Page 1 ROBOTICS Product manual IRC5 Panel Mounted Controller...
Page 2 Trace back information: Workspace 24A version a11 Checked in 2024-03-05 Skribenta version 5.5.019...
Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damage to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Connecting power supply to the control module ..........2.5.6 Connecting communication cables between IRC5 Panel Mounted Drive Module and control module .................. 2.5.7 Connecting fan unit to IRC5 Panel Mounted Drive Module ......2.5.8 Connecting a FlexPendant ................ 2.5.9 Connectors on the computer unit ...............
Page 6 Installation of external operator's panel, IRC5 ..........2.9.3 Installation of external enabling device ............2.9.4 Installation of DeviceNet I/O, Gateways and encoder interface units, IRC5 ..2.9.5 Installation of conveyor tracking module ............2.9.6 Installing the EPS board DSQC 646 for Electronic Position Switches ....
Page 7 CP/CS Harness ..................7.3.4 Cables customer power/customer signal ............. 7.3.5 Other customer cables ................7.3.6 Additional cables ..................Circuit diagrams Circuit diagrams ....................Index Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
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Page 9: Overview Of This Manual
• maintenance personnel. • repair personnel. Prerequisites Maintenance/repair/installation personnel working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. References Reference Document ID Product manual - IRC5 3HAC047136-001...
Page 10 Updated cable list with revised option numbers in section Cables customer power/customer signal on page 268. • Removed section Refurbish. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 11 Information regarding power supply system requirements has been improved in sections Isolation transformer on page 65 Mains line filter on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 12 Information about Ethernet Switch updated in Control module parts on page 253. • Information about SD card updated in Computer unit parts on page 257. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 13: Product Documentation
Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
Page 14 The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 15: Network Security
ABB Ltd and its entities are not liable for damage and/or loss related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.
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Page 17: Safety
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. The information does not cover how to design, install and operate a robot system, nor does it cover all peripheral equipment that can influence the safety of the robot system.
Page 18: Safety Data
The safety related parts of robot and controller are e.g. the following stop circuits: • Enabling device • Emergency stop on operator panel Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 19 EN ISO 13849-1 Annex C, D and E resulting in the values as specified in the following table. See the SISTEMA/ABB FSDT libraries for details of the safety functions. IRC5 Single and IRC5 Panel Mounted Controller Safety function...
Page 20 1.35x10E-07 Conclusion according to EN ISO 13849-1:2015 The IRC5 controller safety system has a safety category 3 with performance level PL d according to EN ISO 13849-1 using the simplified method of chapter 4.5.4 of EN ISO 13849-1 and thus fulfils the safety performance requirement of the robot safety standard EN ISO 10218-1.
Page 21: Requirements On Personnel
The plant liable must make sure that the personnel is trained on the robot, and on responding to emergency or abnormal situations. Personal protective equipment Use personal protective equipment, as stated in the instructions. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 22: Safety Signals And Symbols
NOTE Signal word used to indicate important facts and conditions. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 23 Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 24: Safety Symbols On Controller Labels
Label Description Read the user manual before use. xx1400001152 CE label xx1800000835 UR certified (component) xx1400002060 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 25 Rating label (example) xx1400001163 Lifting instruction for the IRC5 controller. xx1400001157 Required installation space. xx1400001155 Electrical shock xx1400001151 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 26 High voltage inside the module even if the main switch is in the OFF position. xx1400001156 ESD sensitive components inside the controller. xx1400001162 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 27: Robot Stopping Functions
Depending on controller variant, there can be one or two inputs for the protective stop function. See the product manual for the robot controller. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 28 The emergency stop function is a complementary protective measure and shall not be applied as a substitute for safeguarding measures or safety functions. Note For IRC5, a safety input on the panel board that is initiated, must remain active for at least 1.5 s. Stop category configuration for IRC5 The stop category for the safety input can be configured, see Technical reference manual - System parameters.
Page 29: About Emergency Stop
1 Inspect the machinery in order to detect the reason for the emergency stop device actuation. 2 Locate and disengage the emergency stop device or devices that initiated the emergency stop function. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 30: Enabling Device And Hold-To-Run Functionality
In case of hazard, release or compress the three-position enabling device. How to use the hold-to-run function for manual high speed mode is described in the operating manual for the controller. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 31: Robot Operating Modes
Teach or tune programmed manipulator positions The mode manual high speed The mode manual high speed, is used for program verification only. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 32 Setting program pointer (to Main, to routine, to cursor, to service routine, etc.) • Starting and stopping program execution • Stepping program execution • Manually adjusting speed (0–100%) Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 33: About The Automatic Mode
Superior Stop, SS Note Prior to allowing the robot to operate in automatic mode, ensure that any suspended safeguards, are returned to full functionality. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 34: Safety During Installation And Commissioning
When the robot is installed at a height, hanging, or other than mounted directly on the floor, there will be additional hazards. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 35 Compressed air • Hydraulics End-effector hazards require particular attention for applications which involve close human collaboration with the robot. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 36 Before the robot system is put into operation, verify that the safety functions are working as intended and that any remaining hazards identified in the risk assessment are mitigated to an acceptable level. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 37: Safety During Operation
An IRC5 controller with a physical key for the mode selector, is designed so that the key fits on all IRC5 controllers, unless unique keys are ordered.
Page 38: Safety During Maintenance And Repair
See safety instructions for the batteries in Material/product safety data sheet - Battery pack (3HAC043118-001). Related information See also the safety information related to installation and operation. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 39: Safety During Troubleshooting
The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. A risk assessment must be done to address both robot and robot system specific hazards.
Page 40: Safety During Decommissioning
See section Decommissioning on page 239. If the robot is decommissioned for storage, take extra precaution to reset safety devices to delivery status. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 41: Installation And Commissioning
2.1 Overview General There are two versions of the IRC5 Panel Mounted Controller(PMC). PMC small is used for small robots and PMC large is used for large robots. The controller always consists of one control module and one drive module.
Page 42 This is particularly important for the safety equipment to maintain the safety integrity of the installation. Equipment The following parts can be delivered with the IRC5 Panel Mounted Controller: Part. no. Description Note...
Page 43 Continued Note Because the parts of the IRC5 Panel Mounted Controller can be mounted with varying space apart, there is no guarantee that the standard cables are long enough. In some cases there may be a need to create your own customized cables.
Page 44: Installation Activities
2.2 Installation activities 2.2 Installation activities Prerequisites The following section details the main steps on how to unload, transport, install and connect the IRC5 Panel Mounted Controller modules. Overview of the installation Action Detailed in Unpack the delivered IRC5 Panel Mounted Unpacking the controller on page 45 Controller.
Page 45: Transporting And Handling
Note If the 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 (-13°F) Max.
Page 46 Complete controller max. 60 kg Control module 14 kg Drive module 40 kg Weight of additional equipment The table below shows the weight for equipment used with the IRC5 Panel Mounted Controller: Equipment Weight Transformer 13-51 kg Inductor 5.2 kg...
Page 47 Continued Cabinet cooling If the cabinet where the IRC5 Panel Mounted Controller is mounted needs cooling depends on the power dissipation and the surface area of the cabinet. A heat test is necessary to get any exact answers. A rough estimation can be made using the following calculations.
Page 48: The Unit Is Sensitive To Esd
The location of the wrist strap button is shown in the following illustration. Wrist strap button There is an additional wrist strap button on the main computer. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 49: On-Site Installation
The fan to the right creates an air flow though the air channel behind the controller, where the brake resistor bleeder is located. The two fans to the left creates an air flow though the controller modules. xx1100000537 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 50: Installation, Irc5 Panel Mounted Controller
2.4.2 Installation, IRC5 Panel Mounted Controller Dimensions for PMC small The illustration below shows the required installation space for the PMC small. xx0600003314 xx0700000031 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 51 Dimensions for PMC large The illustration below shows the required installation space for the PMC large. M5 (8x) xx1100000533 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 52 2 Installation and commissioning 2.4.2 Installation, IRC5 Panel Mounted Controller Continued xx1100000534 Dimensions for transformers xx0900000952 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 53 2 Installation and commissioning 2.4.2 Installation, IRC5 Panel Mounted Controller Continued Dimensions for inductor xx1100000561 Dimensions for line filter xx1100000563 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 54 For the air flow to function properly, the Control Module and the Drive Module of PMC small must be mounted according to following figure. xx1300001944 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 55 Note The Control Module and Drive Module must be mounted and connected to the same earth. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 56 Continued Installing the modules in a cabinet The IRC5 Panel Mounted Controller modules should be mounted on a rack system in a cabinet. The recommended minimum depth of the cabinet is 400 mm for PMC small and 500 mm for PMC large. The cabinet must fulfill the requirements specified Protection class on page The following procedure details how to install the IRC5 Panel Mounted modules.
Page 57 Always use and store the FlexPendant in such a way that the cable does not become a tripping hazard. When not using the device, place it so it does not accidentally fall. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 58: Connections
Ethernet, according to the standard specification of the respective bus. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 59 Multi wire 4 pair 1.0//17 Multi wire 6 pair 1.0//17 Multi wire 9 pair 1.0//17 0.75//18 three phase 1.0//17 three phase 10.3 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 60 • Cables carrying analog low-level signals is another exception where the shield should be grounded at only one end. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 61 Shield pigtail termination, as shown below, shall be avoided. If a pigtail connection cannot be avoided, make it as short as possible. xx1700001321 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 62 The following figure shows 2 examples on how protective earth and the signal cable screens can be connected: External unit Control cabinet Example 1 Example 2 xx1200000960 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 63 V max voltage and 125 V nominal voltage. The resistor should be 100 Ω, and the capacitor should be 1W 0.1 - 1 µF (typically 0.47 µF). Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 64: Power Supply System Requirements
PE and an N conductor. xx1700001311 xx1700001310 Not recommended power supply systems The following systems are not recommended by ABB: TT system (separate ground rods) Resistance grounded secondary system If this kind of system must be used, the If this kind of system must be used, the...
Page 65 TT system (separate ground rods) Resistance grounded secondary system xx1700001312 xx1700001313 Not allowed power supply systems The following systems are not allowed by ABB: Un-symmetric system IT system (ungrounded secondary) These transformers provide un-symmetric The voltage between phases and ground is phase voltages with respect to ground.
Page 66 A Primary/input B Secondary/output Mains line filter A mains line filter is included in the IRC5 Panel Mounted controller, ensuring compliance with EN/IEC 61000-6-4. Additional types of external filters may be used, provided they are approved by regional standards. For further information refer to regional power supply standards.
Page 67: Connecting Power Supply To Pmc Small
The contents are defined in section Standard toolkit, IRC5 on page 249. Circuit diagram Circuit diagrams on page 273. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 68 Separate the power supply 2-phase wires from the 3-phase wires. These are disturbing on the Line filter LOAD side. Route, strap and connect the earth cable to PE. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 69: Connecting Power Supply To Pmc Large
Power supply 3 x 400-480V Power supply 230V (2 phase) Power supply 230V from the Drive Module to the Control Module Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 70 2.5.4 Connecting power supply to PMC large Continued Rated voltage and current To find the rated voltage, the full load current, and interrupting capacity of the IRC5 Panel Mounted Controller, see the name plates on the side of the control module and drive module.
Page 71 Connect the incoming power to the Line filter (LINE). xx0600003315 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 72 Separate the power supply 2-phase wires from the 3-phase wires. These are disturbing on the Line filter LOAD side. Route, strap and connect the earth cable to PE. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 73: Connecting Power Supply To The Control Module
PMC large: xx1100000513 • D: 230V power supply from the drive module to the control module Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 74 X1. • phase 1 to G2.X1:1 • earth to G2.X1:3 • phase 2 (N) to G2.X1:5 Connect incoming earth to PE. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 75: Connecting Communication Cables Between Irc5 Panel Mounted Drive Module And Control Module
2 Installation and commissioning 2.5.6 Connecting communication cables between IRC5 Panel Mounted Drive Module and control module 2.5.6 Connecting communication cables between IRC5 Panel Mounted Drive Module and control module Location PMC small: xx0600003294 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB ©...
Page 76 2 Installation and commissioning 2.5.6 Connecting communication cables between IRC5 Panel Mounted Drive Module and control module Continued PMC large: xx1100000486 Ethernet cable Panel board/Contactor interface board cable Harness AUX contact, XP/XS38. Only for SafeMove2. Required equipment Equipment Art. no.
Page 77 2 Installation and commissioning 2.5.6 Connecting communication cables between IRC5 Panel Mounted Drive Module and control module Continued Equipment Art. no. Note Standard toolkit Described in section Standard toolkit. Circuit diagram Circuit diagrams on page 273. Connecting the Ethernet cable Use this procedure details connect the Ethernet cable between the drive module and control module.
Page 78: Connecting Fan Unit To Irc5 Panel Mounted Drive Module
2 Installation and commissioning 2.5.7 Connecting fan unit to IRC5 Panel Mounted Drive Module 2.5.7 Connecting fan unit to IRC5 Panel Mounted Drive Module Note For PMC large, the fan unit is already connected at delivery. Location xx0600003323 Control module...
Page 79 2 Installation and commissioning 2.5.7 Connecting fan unit to IRC5 Panel Mounted Drive Module Continued Connecting fan unit to drive module Use this procedure to connect the fan unit to the drive module. Action Note/Illustration Connect fan unit to drive module E1.XP1...
Page 80: Connecting A Flexpendant
Software on page 81 rect software installed. If an update is needed, this is shown. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 81 If the update is available on the controller, then the FlexPendant will update itself when connecting it to the controller. Once the add-in is updated, the FlexPendant can be connected to other IRC5 controllers with the same RobotWare version without requiring additional updates.
Page 82: Connectors On The Computer Unit
Service port test middle The service port is intended for service engineers and programmers connecting directly to the controller with a PC. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 83 Some network services, like FTP and RobotStudio, are enabled by default. Other services are enabled by the respective RobotWare application. Note The WAN port cannot use any of the following IP-addresses which are allocated for other functions on the IRC5 controller: • 192.168.125.0 - 255 •...
Page 84 2.5.9 Connectors on the computer unit Continued LAN 2 can only be used as private network to the IRC5 controller. Isolated LAN 3 or LAN 3 as part of the private network (only for RobotWare 6.01 and later) The default configuration is that LAN 3 is configured as an isolated network. This allows LAN 3 to be connected to an external network, including other robot controllers.
Page 85 USB on the X10 connector for connecting USB memory devices. The USB ports on the X11 connector are intended for internal use. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 86: Connecting A Serial Channel To The Controller
The serial channel connector is located on the expansion board in the computer unit as shown below. xx1300000610 COM1 CONSOLE Note The CONSOLE connector is used for debugging purposes only. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 87 Connect the adapter to the serial channel A cable is needed between the serial connector. channel connector and the adapter. xx1300000854 A cable B adapter Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 88: Closing The Automatic Stop Circuit
To bypass Automatic stop circuit, 3-pole jumpers are enclosed in bag 3HAC078549-001 with corresponding instruction 3HAC078652-001. See the circuit diagram, 3HAC026871-020. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 89: Connection Of The Motors On/Motors Off Circuit
SS (superior stop, same function as GS) AS (Automatic mode safeguarded space stop) ED (FlexPendant three-position enabling device) Manual mode Automatic mode Operating mode selector Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 90 As long as the two channels of AS, GS, SS, and ES are not in identical state, the robot will remain in protective stop and MOTORS OFF mode. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 91 < 5 V External supply of GS/AS/SS Max. + 35 VDC Min. - 35 VDC GS/AS/SS Filter time 2.0 ms Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 92 When connecting for example a safety PLC to a safety stop, make sure that the safety check pulses not exceeds 2.0 ms, otherwise a safety relay must be connected in between. See the following illustration. xx0800000130 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 93 Run chain 1 top Internal ES2 internal Run chain 2 top Emergency stop output 1 Emergency stop output 2 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 94 Max. voltage 48 VDC Max. current Max. potential in relation to the cabinet earthing 300 V and other signal groups. Signal class Control signals Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 95: Programmable Stop Functions
Note Only safety rated input signals are allowed to be used for safety. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 96 The Program Pointer will be moved to Main and if run- ning mode is continuous, the pro- gram will be restarted. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 97 The robot might make a limited move when restarted. WARNING The revolution counters might need to be updated after a colli- sion to ensure path accuracy. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 98: Connection Of External Safety Relay
The following figure shows an example of how to connect an external safety relay. xx0100000246 Robot 1 Robot 2 ES (emergency stop) relay External Safety relay To other equipment Safety gate Cell ES (emergency stop) Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 99: Connection Of Drive Module Disconnect, By Limit Switch
The contactor interface board unit is located in the Panel Mounted Drive Module as shown below. PMC small: xx0600003241 Contactor interface board Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 100 Select the type Drive Module User Data. Set the parameter for selected drive module to YES. Restart the system. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 101 The following procedures details how to connect a remote switch. Action Note/illustration Make sure that the system is in the MO- TORS_OFF state. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 102 Note/illustration Disconnect the jumpers from the connector X22. Connect the wires to the connector X22 according to the diagram on the right. xx0500002091 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 103: Connecting A Limit Switch Override Push Button
Circuit diagram Circuit diagrams on page 273. Note The parts needs to be ordered separately from ABB and are not part of an option package. Procedure The following procedure details how to connect a Limit switch override circuit in the controller.
Page 104 Fit the connector to the X23 connector on the contactor interface board. xx0600003250 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 105: Drive System
2 Installation and commissioning 2.6.1 Drive functions, general 2.6 Drive system 2.6.1 Drive functions, general General The robot is powered by power electronics found in the IRC5 Panel Mounted Controller. Location of drive unit PMC small: xx0600003244 Main Drive Unit...
Page 106 How to replace the drive unit for PMC large is described in section Replacement of Main Drive Unit for PMC large on page 193. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 107: Memory Functions
2.7 Memory functions 2.7.1 Memory functions General The controller is fitted with an SD-card memory containing ABB Boot Application software. The SD-card memory is located inside the computer unit. For more information on how to replace the SD-card memory, see...
Page 108: Connecting A Usb Memory
2.7.2 Connecting a USB memory 2.7.2 Connecting a USB memory Handling USB Handling of USB memory is described in Operating manual - IRC5 with FlexPendant. Location on FlexPendant The USB port on the FlexPendant is located behind a rubber cover.
Page 109: I/O System
2.8 I/O system 2.8.1 Definition of fieldbuses, IRC5 General The IRC5 Controller may be fitted with a number of different fieldbus adapters and fieldbus master/slave boards. In the standard form, no fieldbus is mounted to the controller. Fieldbus master/slave boards On the main computer unit there are slots available for installing a master/slave board.
Page 110 Assembled expansion board for fieldbus adapters, without adapter. Description Art. no. Type designation AnybusCC / RS232 expansion 3HAC046408-001 DSQC1003 board Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 111 Application manual - PROFIBUS Anybus Device 3HAC050965-001 Application manual - PROFIBUS Controller 3HAC050966-001 Application manual - PROFIenergy Device 3HAC050967-001 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 112 2.8.1 Definition of fieldbuses, IRC5 Continued Manual title Art. no. Application manual - PROFINET Anybus Device 3HAC050968-001 Application manual - PROFINET Controller/Device 3HAC065546-001 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 113: Devicenet I/O Units
2 Installation and commissioning 2.8.2 DeviceNet I/O units 2.8.2 DeviceNet I/O units General The IRC5 controller may be fitted with DeviceNet I/O or encoder units. These are configured in an identical way. xx0600003256 I/O or encoder units Mounting rail Connection terminal XT31 Standard configuration In the standard form, no fieldbus is mounted to the controller.
Page 114 The application manual for the different I/O buses re- DeviceNet I/O units. spectively, see listing in Definition of fieldbuses, IRC5 on page 109. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 115: Conveyor Tracking Module
2 encoders and 4 camer- Two connector kits are needed to handle additional encoders and cameras. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 116 The table below gives references to additional information: Information: Found in: How to install and configure Convey- Application manual - Conveyor tracking, or Tracking. 3HAC050991-001 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 117: Installation Of Add-Ons
For PMC, drive units for additional motors cannot be installed. For more information about installing additional Drive Modules, see Application manual - MultiMove. For more information about stacking modules and process modules, see Product specification - Controller IRC5. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB...
Page 118: Installation Of External Operator's Panel, Irc5
2 Installation and commissioning 2.9.2 Installation of external operator's panel, IRC5 2.9.2 Installation of external operator's panel, IRC5 Overview External operator’s panels can be either simply a panel or a panel box. See illustrations below. Note When ordering the external operator's panel as an add-on, the external operator's panel is delivered empty together with labels and blanking plugs.
Page 119 2 Installation and commissioning 2.9.2 Installation of external operator's panel, IRC5 Continued External operator’s panel box (option 733-4) xx1000000954 Wall cabinet Front panel Blanking plug for FlexPendant Blanking plug for actuator red Emergency stop button Motor ON button Mode switch...
Page 120 2 Installation and commissioning 2.9.2 Installation of external operator's panel, IRC5 Continued Procedure The procedure below details how to install the external control panel. Action Info/Illustration DANGER Before doing any work inside the cabinet, disconnect the mains power. For more in-...
Page 121: Installation Of External Enabling Device
2.9.3 Installation of external enabling device Overview IRC5 is delivered with one enabling device but have the possibility to connect one additional external enabling device (cannot be ordered from ABB Robotics). When an external enabling device is used together with the three-position enabling device on the teach pendant, both enabling devices must be enabled to be able to operate the manipulator in manual mode.
Page 122 2 Installation and commissioning 2.9.3 Installation of external enabling device Continued with IRC5’s enabling device chain is above 55 years. See safety related performance for the enabling device chain below. Performance of IRC5 original enabling device chain The safety-related performance of the enabling device chain, without the external enabling device, is as follows: •...
Page 123: Installation Of Devicenet I/O, Gateways And Encoder Interface Units, Irc5
2 Installation and commissioning 2.9.4 Installation of DeviceNet I/O, Gateways and encoder interface units, IRC5 2.9.4 Installation of DeviceNet I/O, Gateways and encoder interface units, IRC5 Location The DeviceNet I/O units, Gateway or encoder interface units to be installed are shown in the illustration below.
Page 124: Installation Of Conveyor Tracking Module
CONNECTOR KIT - DSQC 2000 3HNA029345-001 Application manual - Conveyor 3HAC050991-001 tracking Standard toolkit Standard toolkit, IRC5 on page 249. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 125 Connect wires to the encoder and camera Described in the Application manual - Con- connectors as required. veyor tracking. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 126: Installing The Eps Board Dsqc 646 For Electronic Position Switches
Illustration The EPS board should be mounted behind the axis computer. PMC small: xx1000000979 EPS board Axis computer Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 127 The unit is sensitive to ESD. Before handling the unit read the safety inform- ation in section The unit is sensitive to ESD on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 128 EPS board can be fitted be- hind the axis computer. xx0900000030 • A: axis computer • B: attachment screws Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 129 Fit the EPS board in the same place as the axis computer was before. xx0600003204 • A: EPS board • B: attachment screws Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 130 EPS board. Connect the short Ethernet cable between the EPS board and the axis computer. xx0600003218 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 131 Connect the split cable to the EPS board and the axis computer. xx0600003208 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 132 A: I/O Connector • B: Plug contact • C: Power supply • D: 5 safe outputs (10 signals) • E: Sync switch (dual signal) Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 133: Installing The Safemove Board Dsqc 647
- that is, only one of these two options can be installed and used. Location The SafeMove board should be mounted behind the axis computer. PMC small: xx1000000980 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 134 The unit is sensitive to ESD. Before handling the unit read the safety inform- ation in section The unit is sensitive to ESD on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 135 • A: SMB1 cable • B: SMB2 cable • C: Ethernet cables Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 136 SafeMove board can be mounted on these brack- ets. xx1000000981 • A: mounting brackets • B: attachment screws Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 137 Fit the axis computer on the SafeMove board. xx0900000441 • A: Axis computer • B: SafeMove board • C: attachment screws (4 pcs) Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 138 SafeMove board. xx0800000031 • A: SMB1 cable (robot) • B: SMB2 cable (external axes) Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 139 Connect the split cable to the SafeMove board and the axis computer. xx0800000028 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 140 SafeMove board (X13) and the con- tactor interface board (X21) xx0800000033 Contactor interface board: xx0800000105 • A: limit switch cable Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 141 B: 8 safe outputs (16 signals) • C: 8 safe inputs (16 signals) • D: Sync switch (dual signal) • E: Override operation input (dual sig- nal) Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 142: Testing
When the installation is complete, perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 143: Maintenance
3 Maintenance 3.1 Maintenance schedule for the IRC5 controller 3 Maintenance 3.1 Maintenance schedule for the IRC5 controller General The controller must be maintained at regular intervals to ensure its function. The activities and intervals are described in this section.
Page 144: Inspection Activities
Inspection The procedure below describes how to inspect the IRC5 controller. WARNING Please observe the following before commencing any repair work on the IRC5 controller, or units connected to the controller: • Switch off all electric power supplies with the power switch! •...
Page 145: Cleaning Activities
• Never use compressed air or spray with a high pressure cleaner. • Never leave the door open when cleaning the exterior. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 146: Cleaning The Flexpendant
Clean the touch screen This section describes how to clean the touch screen. Action Info/Illustration Lock the screen. en0400001221 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 147 Do not spray with a high pressure cleaner. • Do not clean the device, operating panel and operating elements with compressed air, solvents, scouring agent or scrubbing sponges. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 148: Function Tests
After the test, release the emergency stop button and press the motors on button to reset the emergency stop state. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 149: Function Test Of Mode Switch
If the event message 10015 Manual mode selected is not shown, the test failed and the root cause of the failure must be found. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 150: Function Test Of Three-Position Enabling Device
10012 Safety guard stop state does not appear • if the event message 90224 En- abling Device conflict appears Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 151: Function Test Of Motor Contactors K42 And K43
If the event message 90227 Motor contact- or conflict appears, the test is failed and the root cause of the failure must be found. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 152: Function Test Of Brake Contactor K44
If the event message 37101 Brake failure appears, the test is failed and the root cause of the failure must be found. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 153: Function Test Of Automatic Stop
90225 Auto Stop conflict appears in the event log, then the test has failed and the root cause of the failure must be found. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 154: Function Test Of General Stop
• if the event message 90206 General Stop open does not appear • if the event message 90226 General Stop conflict appears Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 155: Function Test Of Superior Stop
• if the event message 90215 Superior Stop open does not appear • if the event message 90220 Superior Stop conflict appears Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 156: Function Test Of Limit Switch
Perform validation of the function Safe Axis Speed. See Application manual - SafeMove1. If this test is passed the limit switch works as intended. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 157: Function Test Of Reduced Speed Control
To get accurate results, use sensors or I/O signals to measure the time. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 158 This page is intentionally left blank...
Page 159: Repair
4.1 Overview General There are two versions of the IRC5 Panel Mounted Controller. PMC small is used for small robots and PMC large is used for large robots. The controller always consists of one control module and one drive module.
Page 160 This is particularly important for the safety equipment to maintain the safety integrity of the installation. Note When replacing a part on the IRC5 Panel Mounted Controller, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.
Page 161: Replacement Of Panel Board
Before doing any work inside the cabinet, discon- nect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 162 The unit is sensitive to ESD on page Refit the panel board unit. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 163 Reconnect all connectors. Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 164: Replacement Of I/O Units And Gateways
See references to these procedures in the tools required. step-by-step instructions below. Circuit diagram Circuit diagrams on page 273. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 165 Reconnect all connectors disconnected during removal. Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 166: Replacement Of Backup Energy Bank
4 Repair 4.4 Replacement of backup energy bank 4.4 Replacement of backup energy bank Location The illustration below shows the location of the backup energy bank in the IRC5 controller. xx1300001949 Backup energy bank Required equipment Equipment Note Backup energy bank...
Page 167 Refit the front with the Panel Board Unit. Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 168: Replacement Of Computer Unit
See references to these procedures in the tools required. step-by-step instructions below. Circuit diagram Circuit diagrams on page 273. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 169 The procedure below details how to remove the computer unit. Note If possible, do a backup of the system before removing the computer unit. For information on how to do a backup see Operating manual - IRC5 with FlexPendant. Action...
Page 170 Before doing any work inside the cabinet, disconnect the mains power. For more information, see Electrical safety on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 171 Refit the front with the Panel Board Unit. Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 172: Replacement Of Pciexpress Boards In The Computer Unit
SafeMove2. Standard toolkit The contents are described in sec- tion Standard toolkit, IRC5 on page 249. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 173 The fan cable must not be stretched. xx1300000684 A Attachment screws (4 pcs.) B Upper cover Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 174 The unit is sensitive to ESD. Before hand- ling the unit read the safety information in section The unit is sensitive to ESD on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 175 PCIexpress board. Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 176: Replacement Of Expansion Board In The Computer Unit
Before doing any work inside the cabinet, disconnect the mains power. For more in- formation, see Electrical safety on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 177 CAUTION Always grip the expansion board around the edges to avoid damage to the board or its components. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 178 Reconnect any cable to the fieldbus ad- apter. Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 179: Replacement Of Fieldbus Adapter In The Computer Unit
AnybusCC PROFINET slave 3HAC031670-001 DSQC 688 fieldbus adapter PROFINET communication is de- scribed in Application manu- al - PROFINET Anybus Device Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 180 The unit is sensitive to ESD on page Disconnect any cables to/from the fieldbus adapter. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 181 B Fastening mechanism Grip the loosened attachment screws and gently pull the fieldbus adapter straight out. xx1500001755 A Fieldbus adapter Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 182 A Fieldbus adapter CAUTION Always grip the fieldbus adapter around the edges to avoid damage to the adapter or its components. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 183 Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 184: Replacement Of Fan In Computer Unit
Before doing any work inside the cabinet, disconnect the mains power. For more in- formation, see Electrical safety on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 185 Before doing any work inside the cabinet, disconnect the mains power. For more in- formation, see Electrical safety on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 186 The fan cable must not be squeezed. Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 187: Replacement Of Sd-Card Memory In Computer Unit
DSQC1024/DSQC1094. Use the backup and restore function to move data from DSQC1018 to DSQC1024/DSQC1094. CAUTION Reformatting the SD-card or modifying the disk partition can cause irreparable boot-up problems. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 188 Make sure that the SD-card memory is correctly oriented before inserting it. Otherwise the SD-card memory or the SD-card memory slot may be damaged. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 189 Gently push the SD-card memory with your finger until it clicks into place. Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 190: Replacement Of Drive Unit For Pmc Small
See references to these procedures in the step- the tools required. by-step instructions below. Circuit diagram Circuit diagrams on page 273. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 191 Remove the drive unit after unscrewing its attachment screws . xx0600003248 Parts: • A: drive unit • B: attachment screws Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 192 Refit the front (axis computer/drive system power supply unit) Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 193: Replacement Of Main Drive Unit For Pmc Large
See references to these procedures in the step- the tools required. by-step instructions below. Circuit diagram Circuit diagrams on page 273. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 194 Loosen the cable from the Main Drive Unit by turning the cable straps in the arrows direction. xx1100000560 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 195 Refit the front (axis computer/drive system power supply unit) Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 196: Replacement Of Axis Computer
The illustration below shows the location of the axis computer in the controller. PMC small: xx0600003240 PMC large: xx1100000492 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 197 Before doing any work inside the cabinet, disconnect the mains power. For more in- formation, see Electrical safety on page Fit the new axis computer. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 198 Reconnect all the connectors. Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 199: Replacement Of Eps Board Dsqc 646 For Electronic Position Switches
For more information, see Application manual - Electronic Position Switches. Location The EPS board is mounted behind the axis computer. PMC small: xx1000000979 EPS board Axis computer Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 200 The unit is sensitive to ESD. Before hand- ling the unit read the safety information in section The unit is sensitive to ESD on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 201 Remove the attachment screws of the axis computer and remove the axis computer. xx0900000030 • A: axis computer • B: attachment screws Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 202 The unit is sensitive to ESD on page If not already in place, fit the EMC strips on the EPS board. xx0700000087 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 203 Perform the function tests in section Func- tion tests on page 148 to verify that the basic safety features (e.g. emergency stop) work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 204: Replacement Of Safemove Board Dsqc 647
Application manual - SafeMove1. Location The SafeMove board is mounted behind the axis computer. PMC small: xx1000000980 SafeMove board Axis computer Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 205 Disconnect the cables connected to the SafeMove board and the cables between the SafeMove board and the axis com- puter. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 206 Before doing any work inside the cabinet, disconnect the mains power. For more in- formation, see Electrical safety on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 207 • B: SMB2 cable • C: Ethernet cables Refit the SafeMove board and the axis computer. Refit all cables. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 208 Perform the function tests in section Func- tion tests on page 148 to verify that the basic safety features (e.g. emergency stop) work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 209: Replacement Of Safety Module Dsqc1015 For Safemove
Before doing any work inside the cabinet, disconnect the mains power. For more in- formation, see Electrical safety on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 210 Before doing any work inside the cabinet, disconnect the mains power. For more in- formation, see Electrical safety on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 211 Perform a Cyclic Brake Check. See Application manual - Functional safety and SafeMove2. Lock the SafeMove configuration file. See Application manual - Functional safety and SafeMove2. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 212: Replacement Of Contactor Interface Board
4.17 Replacement of Contactor Interface Board Location The illustration below shows the location of the contactor interface board in the controller. PMC small: xx0600003241 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 213 Before doing any work inside the cabinet, disconnect the mains power. For more in- formation, see Electrical safety on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 214 PMC large: xx1100000488 • A: attachment screws Disconnect all connectors. Make a note of any connections. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 215 Perform the function tests in section Func- tion tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 216: Replacement Of Drive System Fans
Circuit diagram Circuit diagrams on page 273. Removal Action Note/illustration Disconnect the fan cable. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 217 Reconnect the fan cable. Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 218: Replacement Of Transformer Unit
Electrical safety on page WARNING The transformer weighs between 15 and 40 kg, use a hoist and lifting slings. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 219 Reconnect the mains power supply wires and grounding wires. Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 220: Replacement Of Brake Resistor Bleeder For Pmc Small
Before doing any work inside the cabinet, disconnect the mains power. For more in- formation, see Electrical safety on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 221 Replacement of Contactor Interface Board on page 212 Disconnect the brake resistor bleeder cables. xx0600003291 • A: brake resistor bleeder cable Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 222 Refit the brake resistor bleeder unit to the drive module. Refit the attachment screws (10 pcs) Reconnect the brake resistor bleeder cables. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 223 Refit the front (axis computer/drive system power supply). Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 224: Replacement Of Brake Resistor Bleeder For Pmc Large
Before doing any work inside the cabinet, disconnect the mains power. For more in- formation, see Electrical safety on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 225 • A: brake resistor bleeder cable connector • B: cable gland Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 226 A: attachment screws (4 pcs) Remove the plate on the back of the air channel. xx1100000527 • A: attachment screws Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 227 Action Note/illustration Refit the bleeder to the air channel plate. Tighten the attachment screws for the brake resistor bleeder. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 228 Reconnect all connectors and cables to the drive module. Perform the function tests in section Func- tion tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 229: Replacement Of Power Supply
For more information, see Electrical safety on page Loosen the terminal screws for each connected wire. Remove wires from the terminals. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 230 For more information, see Electrical safety on page Refit the new power supply unit on the DIN-rail. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 231 Fasten the screw terminal screws with correct torque. Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 232: Replacement Of Control Power Supply
Circuit diagram Circuit diagrams on page 273. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 233 Before doing any work inside the cabinet, disconnect the mains power. For more in- formation, see Electrical safety on page Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 234 Refit the front with the Panel Board Unit. Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 235: Replacement Of Drive System Power Supply
The illustration below shows the location of the drive system power supply in the IRC5 controller. PMC small: xx0600003239 PMC large: xx1100000496 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 236 A drive system power supply B cup nut (2 pcs) C attachment screw (2 pcs) Loosen the attachment screws. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 237 Reconnect all connectors to the unit. Perform the function tests in section Function tests on page 148 to verify that the safety features work properly. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 238 This page is intentionally left blank...
Page 239: Decommissioning
To remove all data from the SD card, use the Clean Disk function (part of Recovery Disk function) in RobotStudio. See Operating manual - RobotStudio. Transportation Prepare the robot or parts before transport, this to avoid hazards. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 240: Environmental Information
5.2 Environmental information 5.2 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials should be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources.
Page 241 China RoHS symbol The following symbol shows the information to hazardous substances and the environmental protection use period of IRC5 Panel Mounted Controller according to "Management Methods for the Restriction of the Use of Hazardous Substances in Electrical and Electronic Products (SJ/T 11364-2014) ".
Page 242 This page is intentionally left blank...
Page 243: Reference Information
6 Reference information 6.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 244: Applicable Standards
Safety of machinery - Electrical equipment of machines - Part 1: General requirements Deviations from ISO 10218-1:2011 for IRC5 with MultiMove A deviation exists towards ISO 10218-1:2011, paragraph 5.9 Control of simultaneous motion, for the option MultiMove. See the application manual for MultiMove.
Page 245 Degrees of protection provided by enclosures (IP code) Only valid for arc welding robots. Replaces IEC 61000-6-4 for arc welding robots. Only robots with protection Clean Room. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 246: Unit Conversion
2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 247: Screw Joints
The table below specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess heads. Dimension Tightening torque (Nm) Class 4.8, oil-lubricated M2.5 0.25 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 248: Weight Specifications
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...
Page 249: Standard Toolkit, Irc5
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 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 250: Lifting Accessories And Lifting Instructions
The instructions delivered with the lifting accessories should be stored for later reference. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 251: Open Source And 3Rd Party Components
The third party license terms apply only to the respective software to which the license pertains, and the third party license terms do not apply to ABB products. With regard to programs provided under the GNU general public license and the GNU lesser general public license licensor will provide licensee on demand, a machine-readable copy of the corresponding source code.
Page 252 This page is intentionally left blank...
Page 253: Spare Parts
Bridge connector for panel board X6 3HAC024000-004 Bridge connector for panel board X5 3HAC082466-001 Ethernet switch (for IRC5 and PMC) Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 254 Brake resistor bleeder IRB 140, 340, 3HAC037753-001 Brake resistor bleeder IRB 260 3HAC038440-001 Harness-Power supply/Drive 3HAC024254-005 Ethernet cable strait con Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 255 The table below details parts in the recommended spare part list. Spare part no. Description Type 3HAC025784-001 ADCombi I/O unit DSQC 651 3HAC025917-001 Digital I/O unit DSQC 652 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 256 The table below details parts in the recommended spare part list. Spare part no. Description Note 3HAC026486-001 Additional Module Dig 24V 3HAC026486-002 Additional Module AD Combi Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 257 PROFINET Slave Fieldbus Adapter DSQC 688 3HAC026840-001 PROFIBUS Slave Fieldbus Adapter DSQC 667 3HAC027652-001 Ethernet/IP Slave Fieldbus Adapter DSQC 669 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 258 Harness-TPU Jumper plug 3HAC14178-1 Customer I/O Power supply DSQC 609 3HNE 01586-1 Conveyor Tracking Unit DSQC 377B 3HNA027579-001 CTM-01 Conveyor Tracking Module DSQC2000 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 259: Flexpendant Parts
The exact appearance on the graphics might therefore differ slightly from reality. Note The different versions support many, but not all, versions of the IRC5 controllers/RobotWare versions. Contact your local ABB office for more information about compatibility.
Page 260 Set of stylus 3HAC028357-050 TPU hand strap The extension cables cannot be used together with an external operator panel (option 733-3 or 733-4). Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 261: Manipulator Cables
Control cable power 15 m 210-3 3HAC7996-7 Control cable power 22 m 210-4 3HAC7996-8 Control cable power 30 m 210-5 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 262 IRB 1600/1660ID in standard protection, is available in type A and type B. For details about the robot types, see product manual for the robot. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 263 Foundry: 210-3 and 287-3 Wash: 210-5 and 287-5 3HAC9038-3 Control cable power 22 m Foundry: 210-4 and 287-3 Wash: 210-5 and 287-5 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 264 Art. no. Description Option no. 3HAC026787-001 Control cable power 7 m (435-6 or 435-18 or 435-24 or 435-36) and 210-2 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 265 Option no. 3HAC063487-001 Robot cable power 7 m 210-2 3HAC063488-001 Robot cable power 15 m 210-3 3HAC063489-001 Robot cable power 22 m 210-4 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 266: Fan Cables
(87-1 or 88-1 or 89-1) and 210-4 3HAC022723-006 Harness - Axis 1&2 cooling (87-1 or 88-1 or 89-1) and 210-5 3HAC023599-001 Harness - Axis 1 cooling IRB 6700 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 267: Cp/Cs Harness
Connection of Ethernet, L=7m 859-1 3HAC055518-003 Connection of Ethernet, L=15m 859-2 3HAC055518-004 Connection of Ethernet, L=22m 859-3 3HAC055518-005 Connection of Ethernet, L=30m 859-4 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 268: Cables Customer Power/Customer Signal
Foundry: 94-4, 16-1 and 287-3 Wash: 94-4, 16-1 and 287-5 The option number depends on the protection type of the manipulator. Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 269 Option no. 3HAC8183-1 Cable CP/CS 7 m 94-1, 16-1 and 17-5 3HAC8183-2 Cable CP/CS 15 m 94-2, 16-1 and 17-5 Continues on next page Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 270 Cable CP/CS 22 m 218-9 and 94-3 3HAC14860-4 Cable CP/CS 30 m 218-9 and 94-4 The option number depends on the protection type of the manipulator. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 271: Other Customer Cables
218-5 and 94-3 3HAC030198-005 Internal Customer cable 30 m 218-5 and 94-4 The option number depends on the protection type of the manipulator. Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 272: Additional Cables
L=1.7 m 3HAC025600-005 Cable between control module and drive 761-1 module: L=4 m 3HAC025600-006 Cable between control module and drive 761-3 module: L=30 m Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 273: Circuit Diagrams
The circuit diagrams are not included in this manual, but are available for registered users on myABB Business Portal, www.abb.com/myABB. See the article numbers in the tables below. Controllers Product Article numbers for circuit diagrams Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020 troller Manipulators Product Article numbers for circuit diagrams...
Page 274 Circuit diagram - IRB 6700 / IRB 6790 3HAC043446-005 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 14000 3HAC050778-003 Circuit diagram - IRB 910SC 3HAC056159-002 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 275: Index
235 limit switch, 156 drive unit Lithium PMC large, 193 disposal, 240 PMC small, 190 lock and tag, 35 DSQC1015, 209 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 276 30 function test, 150 recovering from emergency stops, 29 tightening torque, 247 recycling, 240 transportation, 239 reduced speed control troubleshooting Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 277 Index safety, 39 validity and responsibility, 17 upcycling, 240 USB ports, 108 weight, 46 users wrist strap, 43, 48 requirements, 21 Product manual - IRC5 Panel Mounted Controller 3HAC047137-001 Revision: AB © Copyright 2007-2024 ABB. All rights reserved.
Page 280 SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2007-2024 ABB. All rights reserved. Specifications subject to change without notice.

ABB IRC5 Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Decommissioning

6 Reference Information

7 Spare Parts

8 Circuit Diagrams

Quick Links

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Summary of Contents for ABB IRC5

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