ROBOTICS

Product manual
IRC5 Compact
Trace back information:
Workspace 20B version a7
Checked in 2020-05-07
Skribenta version 5.3.033
 Product manual
IRC5 Compact
Design 14

Document ID: 3HAC047138-001

Revision: M

© Copyright 2009-2020 ABB. All rights reserved.

Specifications subject to change without notice.
The information in this manual 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 manual.
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.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.

© Copyright 2009-2020 ABB. All rights reserved.

Specifications subject to change without notice.
 Table of contents

Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 13
Network security ............................................................................................................................... 15

1 Safety 17
1.1 Safety information ............................................................................................. 17
1.1.1 Limitation of liability ................................................................................. 17
1.1.2 Safety data ............................................................................................. 18
1.1.3 Requirements on personnel ...................................................................... 21
1.2 Safety signals and symbols ................................................................................. 22
1.2.1 Safety signals in the manual ...................................................................... 22
1.2.2 Safety symbols on controller labels ............................................................ 23
1.3 Robot stopping functions .................................................................................... 26
1.3.1 Protective stop and emergency stop ........................................................... 26
1.3.2 About emergency stops ............................................................................ 28
1.3.3 Enabling device and hold-to-run functionality ............................................... 29
1.4 Robot operating modes ...................................................................................... 30
1.4.1 About the manual mode ........................................................................... 30
1.4.2 About the automatic mode ........................................................................ 31
1.5 Installation and commissioning ............................................................................ 32
1.6 Operation ........................................................................................................ 34
1.7 Maintenance and repair ...................................................................................... 35
1.8 Troubleshooting ................................................................................................ 36
1.9 Decommissioning .............................................................................................. 37

2 Installation and commissioning 39

2.1 Overview ......................................................................................................... 39
2.2 Installation activities .......................................................................................... 40
2.3 Unpacking the controller ..................................................................................... 41
2.4 On-site installation ............................................................................................ 43
2.4.1 Required installation space ....................................................................... 43
2.4.2 Mounting the FlexPendant holder ............................................................... 45
2.4.3 Mounting the controller in a 19" cabinet ....................................................... 47
2.4.4 The unit is sensitive to ESD ....................................................................... 49
2.5 Buttons and switches ......................................................................................... 50
2.5.1 Buttons and switches on the front panel ...................................................... 50
[Link] Brake release button .................................................................... 51
2.6 Connections ..................................................................................................... 52
2.6.1 Connectors on the IRC5 Compact controller ................................................. 52
[Link] Connectors on the controller .......................................................... 52
[Link] Connecting a FlexPendant ............................................................ 54
[Link] Connectors on the computer unit .................................................... 56
[Link] Connecting a serial channel to the controller .................................... 59
2.6.2 Connecting cables to the controller ............................................................. 61
2.6.3 Power supply system requirements ............................................................ 67
2.6.4 Connecting power supply ......................................................................... 70
2.6.5 Grounding ............................................................................................. 72
2.6.6 Fitting the connector ................................................................................ 73
2.6.7 Descriptions for connectors XS7 - XS17 ...................................................... 75
2.6.8 The MOTORS ON/MOTORS OFF circuit ...................................................... 79
2.6.9 Programmable stop functions .................................................................... 84
2.6.10 Emergency stop output ............................................................................ 87
2.7 Opening the IRC5 Compact controller ................................................................... 88
2.8 Drive system .................................................................................................... 89
2.8.1 Drive functions, general ............................................................................ 89

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Table of contents

2.9 Memory functions .............................................................................................. 90

2.9.1 Memory functions .................................................................................... 90
2.9.2 Connecting a USB memory ....................................................................... 91
2.10 I/O system ....................................................................................................... 93
2.10.1 Definition of fieldbuses, IRC5 .................................................................... 93
2.10.2 DeviceNet I/O units .................................................................................. 97
2.10.3 Conveyor tracking module ........................................................................ 98
2.11 Installation of add-ons ........................................................................................ 100
2.11.1 Installation of external operator's panel ....................................................... 100
2.11.2 Installation of external enabling device ........................................................ 103
2.11.3 Installation of conveyor tracking module ...................................................... 105
2.11.4 Installing the Safety module DSQC1015 for SafeMove .................................... 107
2.11.5 Installing the Connected Services box ......................................................... 112
2.12 Testing ............................................................................................................ 113

3 Maintenance 115
3.1 Maintenance schedule, IRC5 Compact controller .................................................... 115
3.2 Inspection activities ........................................................................................... 116
3.2.1 Inspection of controller ............................................................................. 116
3.3 Changing/replacing activities ............................................................................... 117
3.3.1 Activities ............................................................................................... 117
3.4 Cleaning activities ............................................................................................. 118
3.4.1 Cleaning of the controller cabinet ............................................................... 118
3.4.2 Cleaning the FlexPendant ......................................................................... 119
3.5 Function tests ................................................................................................... 121
3.5.1 Function test of emergency stop ................................................................ 121
3.5.2 Function test of mode switch ..................................................................... 122
3.5.3 Function test of three-position enabling device ............................................. 123
3.5.4 Function test of motor contactors K42 and K43 ............................................ 124
3.5.5 Function test of brake contactor K44 .......................................................... 125
3.5.6 Function test of auto stop ......................................................................... 126
3.5.7 Function test of general stop .................................................................... 127
3.5.8 Function test of reduced speed control ........................................................ 128

4 Repair 129
4.1 Overview ......................................................................................................... 129
4.2 Replacement of safety board ............................................................................... 130
4.3 Replacement of I/O unit ...................................................................................... 133
4.4 Replacement of backup energy bank .................................................................... 135
4.5 Replacement of computer unit ............................................................................. 139
4.6 Replacement of PCIexpress boards in the computer unit .......................................... 144
4.7 Replacement of Safety module DSQC1015 for SafeMove .......................................... 148
4.8 Replacement of expansion board in the computer unit ............................................. 152
4.9 Replacement of fieldbus adapter in the computer unit .............................................. 155
4.10 Replacement of fan in computer unit ..................................................................... 160
4.11 Replacement of SD-card memory in computer unit .................................................. 163
4.12 Replacement of drive unit ................................................................................... 166
4.13 Replacement of axis computer ............................................................................. 170
4.14 Replacement of contactor unit ............................................................................. 173
4.15 Replacement of brake resistor bleeder .................................................................. 175
4.16 Replacement of system fans ............................................................................... 178
4.17 Replacement of Connected Services box ............................................................... 180
4.18 Replacement of Ethernet switch ........................................................................... 186
4.19 Replacement of power supply .............................................................................. 189
4.19.1 Replacement of power distribution unit ........................................................ 189
4.19.2 Replacement of system power supply ......................................................... 194
4.19.3 Replacement of line filter .......................................................................... 199

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 Table of contents

5 Decommissioning 203
5.1 Introduction ...................................................................................................... 203
5.2 Environmental information .................................................................................. 204

6 Reference information 205

6.1 Introduction ...................................................................................................... 205
6.2 Applicable standards ......................................................................................... 206
6.3 Unit conversion ................................................................................................. 208
6.4 Standard toolkit, IRC5 ........................................................................................ 209
6.5 Screw joints ..................................................................................................... 210

7 Spare parts 211

7.1 IRC5 Compact controller .................................................................................... 211
7.2 FlexPendant parts ............................................................................................. 216
7.3 Manipulator cables ............................................................................................ 217

8 Circuit diagrams 221

8.1 Circuit diagrams ................................................................................................ 221

Index 223

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 Overview of this manual

Overview of this manual

About this manual
This manual contains instructions for:
• installing the controller, mechanically as well as electrically.
• maintenance of the controller.
• mechanical and electrical repair of the controller.

Usage
This manual should be used during:
• installation and preparation work.
• maintenance work.
• repair work.

Who should read this manual?

This manual is intended for:
• installation personnel.
• 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
Operating manual - Emergency safety information 3HAC027098-001
Operating manual - IRC5 with FlexPendant 3HAC050941-001
Operating manual - RobotStudio 3HAC032104-001
Operating manual - Getting started, IRC5 and RobotStudio 3HAC027097-001
Operating manual - Troubleshooting IRC5 3HAC020738-001
Application manual - MultiMove 3HAC050961-001
Application manual - Force Control 3HAC050377-001
Application manual - SafeMove1 3HAC050974-001
Application manual - Electronic Position Switches 3HAC050996-001
Application manual - Functional safety and SafeMove2 3HAC052610-001
Technical reference manual - RAPID Instructions, Functions and 3HAC050917-001
Data types
Technical reference manual - System parameters 3HAC050948-001
Product specification - Controller IRC5 3HAC047400-001

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Overview of this manual
Continued

Reference Document ID
See Circuit diagrams on page 221.

Note

The document numbers that are listed for software documents are valid for
RobotWare 6. Equivalent documents are available for RobotWare 5.

Revisions

Revision Description
- First edition.
Released with the new computer unit, DSQC1000.
A • New computer unit, DSQC1018, with two PCI slots and no knockout
plates. No functional change, but affects illustrations.
• Corrections on chapter Repair on page 129.
• Corrected article number for line filter in Replacement of line filter on
page 199.
• Clarified the use of the WAN port in section Connectors on the com-
puter unit on page 56.
B • Added mounting kit as spare part in section Mounting the controller
in a 19" cabinet on page 47.
• Some changes on how the ports can be configured and used is de-
scribed in section Connectors on the computer unit on page 56.
C Release 15.2.
• Minor corrections.
• Added safety-related information related to mode switch keys, Function
tests on page 121, and Refurbish.
• Updates in section Applicable standards on page 206.
D Release 16.1.
• Updated cable info for IRB 1200 in section Manipulator cables on
page 217.
• Spare parts updated.
• Section Connecting cables to the controller added.
• New Remote service box introduced.
• Safe Move 2 information added.
• Circuit diagrams for Motors ON/OFF updated.
• Minor corrections.
E Release 16.2.
• Added section Installing the Safety module DSQC1015 for SafeMove
on page 107.
• Added information that function tests should be performed after repla-
cing a component.
• Changes in the article names for some spare parts.
• Removed section Refurbish.

Continues on next page

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 Overview of this manual
Continued

Revision Description
F Release 17.1.
• Added sections Function test of reduced speed control on page 128,
and About emergency stops on page 28.
• Updated descriptions of stops in section Protective stop and emergency
stop on page 26.
• Added section Safety data on page 18.
• Updated list of labels in section Safety symbols on controller labels
on page 23.
• New computer unit DSQC1024 is introduced, see Computer unit parts
on page 212.
• Spare parts updated, see Manipulator cables on page 217.
• Added section Grounding on page 72.
• Information regarding new safety board DSQC400E added.
• Minor corrections.
G Release 17.2.
• Updated list of applicable standards.
• Updated section Connecting cables to the controller on page 61.
• Added section Power supply system requirements on page 67.
• Spare parts updated, see Manipulator cables on page 217.
• Removed all references to computer unit DSQC1024.
• Minor corrections.
H Release 18.1.
• Added cautions about not using external power in section Connecting
the cables to the Safety module (hardware switch and 731-1) on
page 110.
• Added information about DSQC 400E in section Emergency stop output
on page 87.
• Updated to correct and consistent naming convention: DSQC
400/DSQC 400E is called Safety board. DSQC1015 is called Safety
module.
• Updated information about DSQC 651 and DSQC 652.
• Added section FlexPendant parts on page 216.
• Safety section restructured.
• Added information about disposal of storage media.
• Clarified the limitations for Isolated Lan 3 in the section Isolated LAN
3 or LAN 3 as part of the private network (only for RobotWare 6.01 and
later) on page 58.
J Release 18.2.
• Updated spare parts for harnesses.
• New computer unit DSQC1024 is added, see Computer unit parts on
page 212.
• Added note in section Replacement of SD-card memory in computer
unit on page 163, that SD-card from DSQC1018 cannot be used in
DSQC1024.

Continues on next page

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Overview of this manual
Continued

Revision Description
K Published in release 19B. The following updates are made in this revision:
• Updated spare parts numbers for manipulator cables.
• New chapters added: Conveyor tracking module on page 98 and In-
stallation of conveyor tracking module on page 105
• Updated the illustration for the dimension of the footprint.
• Added information in Connecting cables to the controller on page 61.
• Added information about delays on safety inputs in Protective stop
and emergency stop on page 26.
• Updated spare parts number for DSQC 668.
• Updated spare parts and information for Connected Services box.
Remote Service box is renamed to Connected Services box.
L Published in release 19C. The following updates are made in this revision:
• Added information about FlexPendant cables, see Handling the Flex-
Pendant cables on page 55.
M Published in release 20B. The following updates are made in this revision:
• Information regarding power supply system requirements has been
improved in sections Isolation transformer on page 68 and Mains line
filter on page 69.

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 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.
All documents can be found via myABB Business Portal, [Link].

Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.

Technical reference manuals

The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.

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, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.

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Product documentation
Continued

Operating manuals
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.

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 Network security

Network security
Network security
This product is designed to be connected to and to communicate information and
data via a network interface. It is your sole responsibility to provide, and
continuously ensure, a secure connection between the product and to your network
or any other network (as the case may be).
You shall establish and maintain any appropriate measures (such as, but not limited
to, the installation of firewalls, application of authentication measures, encryption
of data, installation of anti-virus programs, etc) to protect the product, the network,
its system and the interface against any kind of security breaches, unauthorized
access, interference, intrusion, leakage and/or theft of data or information. 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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 1 Safety
1.1.1 Limitation of liability

1 Safety
1.1 Safety information

1.1.1 Limitation of liability

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.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.

Spare parts and equipment

ABB supplies original spare parts and equipment which have been tested and
approved. The installation and/or use of non-original spare parts and equipment
can negatively affect the safety, function, performance, and structural properties
of the robot. ABB is not liable for damages caused by the use of non-original spare
parts and equipment.

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1 Safety
1.1.2 Safety data

1.1.2 Safety data

About this section

This chapter describes the necessary safety data required by standard EN ISO
13849-1:2015.

Prevailing directives and standards

For the use of industrial robots and how to protect personnel from being injured,
special regulations must be fulfilled as described in the following directives and
standards:
• Machinery Directive 2006/42/EC
• EN ISO 10218-1:2011
• EN ISO 13849-1:2008 (when explicitly called forth by EN ISO 10218-1:2011
as ISO 13849-1:2006)
• EN ISO 13849-1:2015

Performance level and category

EN ISO 13849-1, which is a B-standard, describes the general concept of
performance level (PL) and category. Each machine or machinery is potentially
dangerous and can cause personal injury. Based on severity of injury and probability
of accident, when using the machine, a certain level of safety performance, so
called required performance level (PLr) can be defined, where level a represents
the lowest risk and level e the highest. According to this, the machine must be
equipped with safety related parts, meeting the required performance level, to
reduce the risk to accepted low level. As specified in EN ISO 10218-1, normally
PL d is required for robots, but depending on the applications a higher requirement
could be needed if a risk analysis will result in PL e.
To comply with a certain PLr, in this case d, the safety related parts of the robots
and controllers must be structurally designed according to specific structure
categories and using reliable components.
In EN ISO 13849-1 it is in detail specified what category and components data,
which must be met, to fulfill PL d. These are:
• Category 3, which is normally fulfilled using double channels
• MTTFD (Mean Time To dangerous Failure) – high
• DC (Diagnostic Coverage) – low or medium
• CCF (Common Cause Failures) – better than 65 scores according to Annex
F

Performance level for ABB IRC5 controller

To verify that robots and controller comply with at least PL d a self assessment
has been carried out and documented in a Technical Report. The essential
conclusions are accounted for below.
The safety related parts of robot and controller are e.g. the following stop circuits:
• Enabling device
• Emergency stop on operator panel
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 1 Safety
1.1.2 Safety data
Continued

• Emergency stop on FlexPendant

• Limiting robot motion
• Protective stops
• SafeMove2
For the overall design and structure, the category 3 has been verified and meeting
the requirements of CCF.
Each of the stop circuits includes different components like enabling switch, panel
board, contactor board, relays etc. For each of these the MTTFD and DC have been
calculated according to 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.

IRC5C Compact

Safety function Calculated MTTFD DCavg

[years]
Emergency stop inputs 56 Medium
Automatic stop input 59 Medium
General stop input 59 Medium
Superior stop input 59 Medium
Limiting switch input 176 Medium
(without customer connection)
Three-position enabling device inputs 46 Medium
Emergency stop status outputs 263 Medium
SafeMove2 functions (option)
Protective stop category 0 52 Medium
Protective stop category 1 370 Low
Emergency stop category 0 52 Medium
Emergency stop category 1 370 Low
Emergency stop safe fieldbus output 160 Low
Speed supervision category 0 52 Medium
Speed supervision category 1 370 Low
Speed supervision safe fieldbus output 370 Low
Position supervision category 0 52 Medium
Position supervision category 1 370 Low
Position supervision safe fieldbus output 370 Low

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1 Safety
1.1.2 Safety data
Continued

Based on the values from the previous table of MTTFD values, the corresponding
PFHD can be calculated using the Annex K, table K1 of EN ISO 13849-1:2008.
These are shown in the following table.

IRC5C Compact

Stop circuit Calculated PFHD PL

Emergency stop inputs 1.19x10E-07 d
Automatic stop input 1.03x10E-07 d
General stop input 1.03x10E-07 d
Superior stop input 1.03x10E-07 d
Limiting switch input 4.29x10E-08 e
(without customer connection)
Three-position enabling device inputs 1.54x10E-07 d
Emergency stop status outputs 4.29x10E-08 e
SafeMove2 functions (option)
Protective stop category 0 1.19x10E-07 d
Protective stop category 1 1.01x10E-07 d
Emergency stop category 0 1.19x10E-07 d
Emergency stop category 1 1.01x10E-07 d
Emergency stop safe fieldbus output 1.01x10E-07 d
Speed supervision category 0 1.19x10E-07 d
Speed supervision category 1 1.01x10E-07 d
Speed supervision safe fieldbus output 1.01x10E-07 d
Position supervision category 0 1.19x10E-07 d
Position supervision category 1 1.01x10E-07 d
Position supervision safe fieldbus output 1.01x10E-07 d

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.
The Common Cause Failure (CCF) is met according to the standard requirements.

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 1 Safety
1.1.3 Requirements on personnel

1.1.3 Requirements on personnel

General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating
substances are not allowed to install, maintain, service, repair, or use the robot.
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 product manual.

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1 Safety
1.2.1 Safety signals in the manual

1.2 Safety signals and symbols

1.2.1 Safety signals in the manual

Introduction to safety signals

This section specifies all safety signals used in the user manuals. Each signal
consists of:
• A caption specifying the hazard level (DANGER, WARNING, or CAUTION)
and the type of hazard.
• Instruction about how to reduce the hazard to an acceptable level.
• A brief description of remaining hazards, if not adequately reduced.

Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
For more information, see standard ISO 13849.
Symbol Designation Significance
DANGER Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.

WARNING Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in serious
injury.

ELECTRICAL Signal word used to indicate a potentially hazardous

SHOCK situation related to electrical hazards which, if not
avoided, could result in serious injury.

CAUTION Signal word used to indicate a potentially hazardous

situation which, if not avoided, could result in slight
injury.

ELECTROSTATIC Signal word used to indicate a potentially hazardous

DISCHARGE (ESD) situation which, if not avoided, could result in severe
damage to the product.

NOTE Signal word used to indicate important facts and

conditions.

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 1 Safety
1.2.2 Safety symbols on controller labels

1.2.2 Safety symbols on controller labels

Introduction to symbols
This section describes safety symbols used on labels (stickers) on the controller.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.

Note

The symbols on the labels on the product must be observed. Additional symbols
added by the integrator must also be observed.

Types of symbols
Both the manipulator and the controller are marked with symbols, containing
important information about the product. This is important for all personnel handling
the robot, for example during installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 23.
The information labels can contain information in text.

Symbols on safety labels

Label Description
Read the user manual before use.

xx1400001152

CE label

xx1800000835

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1 Safety
1.2.2 Safety symbols on controller labels
Continued

Label Description
UR certified (component)

xx1400002060

UL certified (robot with controller)

xx1400002061

Rating label (example)

xx1400001163

Lifting instruction for the IRC5 controller.

xx1400001157

Required installation space.

xx1400001155

Continues on next page

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 1 Safety
1.2.2 Safety symbols on controller labels
Continued

Label Description
Electrical shock

xx1400001151

Disconnect incoming mains before servicing the controller.

xx1400001161

Disconnect incoming mains before servicing the controller

(only for welding equipment).
xx1400001160

Disconnect incoming mains before servicing the controller (for

controllers without UL mains switch).

xx1700000354

High voltage inside the module even if the main switch is in

the OFF position.

xx1400001156

ESD sensitive components inside the controller.

xx1400001162

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1 Safety
1.3.1 Protective stop and emergency stop

1.3 Robot stopping functions

1.3.1 Protective stop and emergency stop

Robot stopping functions

The robot has an emergency stop function and at least one protective stop function.
These functions have provision for the connection of external emergency stops
and protective devices.
The emergency stop function is a complementary protective measure and shall
not be applied as a substitute for safeguarding measures or safety functions.
The stop categories can be re-configured as defined by standards EN ISO
10218-1:2011 and IEC 60204-1:2016.
Emergency stop and protective stop functions are activated through dedicated
safety inputs or safety protocols.
For example, an output from a safety rated presence sensing device output can
be connected to a safety input on the robot controller. This is to initiate a protective
stop of the robot.

Stop categories

Stop category 0 As defined in IEC 60204-1, stopping by immediate removal of

power to the machine actuators.
Stop category 1 As defined in IEC 60204-1, a controlled stop with power avail-
able to the machine actuators to achieve the stop and then re-
moval of power when the stop is achieved.

Safety inputs to initiate a protective stop or an emergency stop

Protective stop and emergency stop inputs will initiate a stop, selectable of category
0 or category 1.
Safety inputs to initiate a Description
stop
Emergency stop (ES) The Emergency Stop is operational in both automatic and
manual mode.
The default configuration is stop category 0. For deviations,
see the product manual for the manipulator.
Automatic stop (AS) The safety input Automatic Stop is only operational in automatic
mode.
The default configuration is stop category 1.
General stop (GS) The safety input General Stop is operational in both manual
mode and automatic mode.
The default configuration is stop category 1.
Superior stop (SS) The safety input Superior Stop is operational in both manual
mode and automatic mode.
The default configuration is stop category 1.
(Superior stop is only available for IRC5.)

Continues on next page

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 1 Safety
1.3.1 Protective stop and emergency stop
Continued

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.
Safety inputs System paramet- Description
er Function
Emergency Stop SoftES SoftES is used to configure the emergency stop in
automatic and manual mode. The default configuration
is FALSE (stop category 0).
Automatic Stop SoftAS SoftAS can be used to configure the protective stop
in automatic mode either as stop category 0 or cat-
egory 1. The default configuration is TRUE (stop cat-
egory 1).
General Stop SoftGS SoftGS can be used to configure the protective stop
in automatic and manual mode, either as stop category
0 or category 1. The default configuration is TRUE
(stop category 1).
Superior Stop SoftSS SoftSS can be used to configure the protective stop
in automatic and manual mode, either as stop category
0 or category 1. The default configuration is TRUE
(stop category 1).

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1 Safety
1.3.2 About emergency stops

1.3.2 About emergency stops

The emergency stops

The purpose of the emergency stop function is to avert actual or impending
emergency situations arising from the behavior of persons or from an unexpected
hazardous event.
The emergency stop function is to be initiated by a single human action.
The emergency stop function is a complementary protective measure and shall
not be applied as a substitute for safeguarding measures and other functions or
safety functions.
The effect of an activated emergency stop device is sustained until the actuator
of the emergency stop device has been disengaged. This disengagement is only
possible by an intentional human action on the device where the command has
been initiated. The disengagement of the device shall not restart the machinery
but only permit restarting.
After actuation and before disengaging the emergency stop device, the machinery
shall be inspected in order to detect the reason for actuation.

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 1 Safety
1.3.3 Enabling device and hold-to-run functionality

1.3.3 Enabling device and hold-to-run functionality

Three-position enabling device

CAUTION

The person using the three-position enabling device is responsible to observe

the safeguarded area for hazards due to robot motion and any other hazards
controlled by the robot.
The three-position enabling device is a manually operated, constant pressure
push-button which, when in center-enabled position, allows potentially hazardous
functions.
The three-position enabling device will when continuously held in center-enabled
position permit robot motion and any hazards controlled by the robot. Release of
or compression past the center-enabled position will stop the hazard, for example,
robot motion.

CAUTION

For safe use of the three-position enabling device, the following must be
implemented:
• The three-position enabling device must never be rendered inoperational
in any way.
• If there is a need to enter safeguarded space, always bring the three-position
enabling device. This is to enforce single point of control.

Hold-to-run function in manual full speed mode

The hold-to-run function for manual full speed allows movement in conjunction
with the three-position enabling device when the button connected to the function
is actuated manually. This hold-to-run function can only be used in manual full
speed mode. In case of hazard, release or compress the three-position enabling
device.
How to use the hold-to-run function for manual full speed mode is described in the
operating manual for the controller.

Note

The manual full speed mode is not available in all markets.

Deviations are listed in the product manual for the manipulator.

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1 Safety
1.4.1 About the manual mode

1.4 Robot operating modes

1.4.1 About the manual mode

The manual mode

Manual mode is a control state that allows for the direct control by an operator.
The operator will through positioning the three-position enabling switch to the
center-position allow for movement of the manipulator.
There are two manual modes:
• Manual reduced speed mode
• Manual high speed mode (optional)

Safeguard mechanisms
• Protective stops through
- Three-position enabling switch
- General Stop, GS
Deviations are listed in the product manual for the controller.

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 1 Safety
1.4.2 About the automatic mode

1.4.2 About the automatic mode

The automatic mode

Automatic mode is an operating mode in which the robot control system operates
in accordance with the task program(s) and therefore not in direct control by an
operator.

Safeguard mechanisms
• Protective stop through
- Automatic Stop, AS
- General Stop, GS
- Superior Stop, SS
Deviations are listed in the product manual for the controller.

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1 Safety
1.5 Installation and commissioning

1.5 Installation and commissioning

National or regional regulations

The integrator of the robot system is responsible for the safety of the robot system.
The integrator is responsible that the robot system is designed and installed in
accordance with the safety requirements set forth in the applicable national and
regional standards and regulations.
The integrator of the robot system is required to perform an assessment of the
hazards and risks.

Layout
The robot integrated to a robot system shall be designed to allow safe access to
all areas during installation, operation, maintenance, and repair.
If robot movement can be initiated from an external control panel then an emergency
stop must also be available.
If the manipulator is delivered with mechanical stops, these can be used for reducing
the working area.
A perimeter safeguarding, for example a fence, shall be dimensioned to withstand
the following:
• The force of the manipulator.
• The force of the load handled by the robot if dropped or released at maximum
speed.
• The maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
The maximum TCP speed and the maximum velocity of the robot axes are detailed
in the section Robot motion in the product specification for the respective
manipulator.
Consider exposure to hazards, such as slipping, tripping, and falling.
Consider hazards from other equipment in the robot system, for example, that
guards remain active until identified hazards are reduced to an acceptable level.

Allergenic material
See the respective product manual for specification of allergenic materials in the
product, if any.

Securing the robot to the foundation

The robot must be properly fixed to its foundation/support, as described in the
product manual.
When the robot is installed at a height, hanging, or other than mounted directly on
the floor, there will be additional hazards.

Electrical safety
The mains power must be installed to fulfill national regulations.

Continues on next page

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 1 Safety
1.5 Installation and commissioning
Continued

The power supply wiring to the robot must be sufficiently fused and if necessary,
it must be possible to disconnect it manually from the mains power.
The power to the robot must be turned off with the main switch and the mains
power disconnected when performing work inside the controller cabinet. Lock and
tag shall be considered.
Hazards due to stored electrical energy in the controller must be considered.
Harnesses between controller and manipulator shall be fixed and protected to
avoid tripping and wear.

Note

Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot.

Safety devices
The integrator is responsible for that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices to a robot system:
• The integrator of the robot system must ensure that emergency stop functions
are interlocked in accordance with applicable standards.
• The integrator of the robot system must ensure that safety functions are
interlocked in accordance with applicable standards.

Other hazards
The risk assessment should also consider other hazards, such as, but not limited
to:
• Water
• Compressed air
• Hydraulics

Verify the safety functions

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.

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1 Safety
1.6 Operation

1.6 Operation

Lock and change of operating mode

To prevent hazard, it is the responsibility of the integrator to make sure that keys
used to lock or change the operating mode are handled only by authorized
personnel.
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.

Safety actuators not in use

Devices with safety actuators that are not connected to the robot or robot system
cannot initiate emergency stops or protective stops. These must be stored out of
reach and sight so that they cannot be mistaken for being in use.

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 1 Safety
1.7 Maintenance and repair

1.7 Maintenance and repair

General
Corrective maintenance must only be carried out by personnel trained on the robot.
Maintenance or repair must be done with all electrical, pneumatic, and hydraulic
power switched off, that is, no remaining hazards.
Never use the robot as a ladder, which means, do not climb on the controller,
manipulator, including motors, or other parts. There are hazards of slipping and
falling. The robot might be damaged.
Make sure that there are no loose screws, turnings, or other unexpected parts
remaining after work on the robot has been performed.
When the work is completed, verify that the safety functions are working as
intended.

Hot components in controller

Parts in the controller can be hot after running the robot. Touching the parts may
result in burns.
Allow the controller to cool down before maintenance or repair.

Hazards related to batteries

Under rated conditions, the electrode materials and liquid electrolyte in the batteries
are sealed and not exposed to the outside.
There is a hazard in case of abuse (mechanical, thermal, electrical) which leads
to the activation of safety valves and/or the rupture of the battery container. As a
result under certain circumstances, electrolyte leakage, electrode materials reaction
with moisture/water or battery vent/explosion/fire may follow.
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge
or expose to temperatures above the declared operating temperature range of the
product. Risk of fire or explosion.
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.

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1 Safety
1.8 Troubleshooting

1.8 Troubleshooting

General
When troubleshooting requires work with power switched on, special considerations
must be taken:
• Safety circuits might be muted or disconnected.
• Electrical parts must be considered as live.
• 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.

Related information
See also the safety information related to installation, operation, maintenance, and
repair.

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 1 Safety
1.9 Decommissioning

1.9 Decommissioning

General
See section Decommissioning on page 203.

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 2 Installation and commissioning
2.1 Overview

2 Installation and commissioning

2.1 Overview

General
The IRC5 Compact controller has all components in one small cabinet. Note that
the appearance of the enclosure of the compact controller may vary depending on
year model.

xx0900000316

Note

When replacing a unit in the controller, report the following data to ABB, for both
the replaced unit and the replacement unit:
• the serial number
• article number
• revision
This is particularly important for the safety equipment to maintain the safety
integrity of the installation.

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2 Installation and commissioning
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 Compact controller.

Overview of the installation

Action Information
1 Unpack the delivered IRC5 Compact con- How to unpack, store and transport the
troller. IRC5 Compact controller is described in
section Unpacking the controller on
page 41.
2 Install the IRC5 Compact controller. How to install the IRC5 Compact controller
is described in section On-site installation
on page 43.
3 Connect the manipulator to the IRC5 How to connect the manipulator to the
Compact controller. IRC5 Compact controller is described in
section Connecting cables to the controller
on page 61.
4 Connect power supply to the IRC5 Com- How to connect power supply is described
pact controller. in section Connecting power supply on
page 70.
5 Connect the FlexPendant to the IRC5 How to connect the FlexPendant is de-
Compact controller. scribed in section Connecting a FlexPend-
ant on page 54.
6 Miscellaneous connections. How to connect MOTORS ON/MOTORS
OFF circuits is described in section The
MOTORS ON/MOTORS OFF circuit on
page 79.
How to connect buses, for example Devi-
ceNet, is described in the Application
manual for the respective bus.
How to connect I/O units to the IRC5
Compact controller is described in the Ap-
plication manual for the respective I/O unit.
How to connect a PC to the controller is
described in manual Operating manual - Ro-
botStudio .
How to connect to a network is detailed in
section Connectors on the computer unit
on page 56.

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 2 Installation and commissioning
2.3 Unpacking the controller

2.3 Unpacking the controller

General
Read the safety regulations and other instructions before unpacking the controller,
see Safety on page 17.
The installation must be done by qualified installation personnel and should conform
to all national and local codes.
When unpacking the cabinet, inspect that it was not damaged during transport.

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. ambient temperature +55°C (+131°F)
Max. ambient temperature (short periods, +70°C (+158°F)
max 24 h)
Max. ambient humidity Maximum 95% at constant temperature.

After storage, the operating conditions must be met for at least 4 hours before
switching on the controller (see Operating conditions on page 41).

Operating conditions
The table below shows the allowed operating conditions for the IRC5 controller:
Parameter Value
Min. ambient temperature 0°C (32°F)
Max. ambient temperature +45°C (113°F)
Max. ambient humidity Maximum 95% at constant temperature.

Weight of controller
The table below shows the weight for the IRC5 controller:
Controller Part Weight
IRC5 Compact Complete controller max. 30 kg

Protection class
The table below shows the protection classes for the IRC5 controller and the
FlexPendant:
Equipment Protection class
IRC5 Compact controller IP20

Continues on next page

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2 Installation and commissioning
2.3 Unpacking the controller
Continued

Equipment Protection class

FlexPendant IP54

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 2 Installation and commissioning
2.4.1 Required installation space

2.4 On-site installation

2.4.1 Required installation space

Dimensions
The following illustration shows the required installation space for the IRC5 Compact
controller.

50
mm
mm
10 0

55
0 mm mm
540
50
mm

xx1400001367

a) Not required if the controller is rack-mounted

• A free space of 50 mm on both left and right side of the controller is required
if the controller is mounted on desk (not rack-mounted).
• A free space of 100 mm on the back of the controller is required to ensure
proper cooling. Do not place customer cables over the fan cover on the back
of the controller (because this makes it difficult to inspect and it leads to
inefficient cooling).

Continues on next page

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2 Installation and commissioning
2.4.1 Required installation space
Continued

The following illustration shows the dimension of the footprint of the IRC5 Compact
controller.

407 21
202,1 204,9

186,8

302
115,2

98,8
xx1400001366

• The feet should only be used for positioning, not for mounting or fastening.

Note

If the IRC5 Compact controller is to be installed in a rack, it must be fastened in

a way that prevents distortion of the controller cabinet. Preferably with angle
bars along the entire side edges of the controller cabinet.

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 2 Installation and commissioning
2.4.2 Mounting the FlexPendant holder

2.4.2 Mounting the FlexPendant holder

Location
One possible placement of the FlexPendant holder is shown in the illustration
below, but it can also be placed at another location.

xx1400001368

Note

Do not position the FlexPendant holder so that it is an obstacle in the place of

work.

Required equipment

Equipment [Link]
FlexPendant holder For spare parts, see Miscellaneous parts
on page 214.

Continues on next page

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2 Installation and commissioning
2.4.2 Mounting the FlexPendant holder
Continued

Mounting the FlexPendant holder

Use this procedure to mount the FlexPendant holder.
Action Note/illustration
1 Remove the protective liner from the tape.

xx0500002546

2 Press the mounting plate with FlexPendant

holder against the surface where it should be
mounted.

Note

The surface must be clean and dry.

Note

For rack mounted IRC5 Compact, do not place the FlexPendant holder on top
of the rack. Find a solution where the FlexPendant is placed so that it cannot fall
to the floor from a high position.

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 2 Installation and commissioning
2.4.3 Mounting the controller in a 19" cabinet

2.4.3 Mounting the controller in a 19" cabinet

General
The IRC5 Compact controller is designed to fit in a 19" cabinet.

xx1400002112

Required equipment

Equipment Information
Mounting kit 3HAC052262-001
Standard toolkit The content is described in section
Standard toolkit, IRC5 on page 209.
Other tools and procedures may be required. See
references to these procedures in the step-by-
step instructions below.

Procedure
Use the following procedure to remove the axis computer.
Action Info/illustration
1 Remove the five feet from the cabinet.

Continues on next page

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2 Installation and commissioning
2.4.3 Mounting the controller in a 19" cabinet
Continued

Action Info/illustration
2 Assemble the mounting brackets.

xx1400002159

3 Fit the right, left and middle mounting

brackets in the 19 inch cabinet.

xx1500000232

4 Insert the IRC5 Compact in the 19 inch cab-

inet so that the latches fit in the recesses in
the back of the mounting brackets. Fasten
the IRC5 Compact to the mounting brackets
with the attachment screws.

xx1400002160

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 2 Installation and commissioning
2.4.4 The unit is sensitive to ESD

2.4.4 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.

Safe handling

Action Note
1 Use a wrist strap. The wrist strap Wrist straps must be tested frequently to ensure
button is located inside the control- that they are not damaged and are operating cor-
ler. rectly.
2 Use an ESD protective floor mat. The mat must be grounded through a current-limit-
ing resistor.
3 Use a dissipative table mat. The mat should provide a controlled discharge of
static voltages and must be grounded.

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2 Installation and commissioning
2.5.1 Buttons and switches on the front panel

2.5 Buttons and switches

2.5.1 Buttons and switches on the front panel

Front panel controls

The following illustration describes the buttons and switches on the front panel of
the IRC5 Compact controller.

A B C D E

xx1400001369

A Main power switch

B Brake release button (under the cover) for IRB 120. The IRC5 Compact used
with other robots has no brake release button, only a blanking plug, since the
robot has a brake release button.
C Mode switch
D Motors on
E Emergency stop

The brake release button is described in section Brake release button on page 51.
The other buttons and switches are described in Operating manual - IRC5 with
FlexPendant.

Continues on next page

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 2 Installation and commissioning
[Link] Brake release button

[Link] Brake release button

Location

xx1400001620

A Brake release button (under the cover) for IRB 120.

IRB 120
An IRC5 Compact controller used with IRB 120 has a brake release button located
under a plastic cover. At power on state, open the cover and press the brake release
button to change the positions of the manipulator axes manually.

WARNING

Be very careful when releasing the brakes. The axes may fall immediately and
can cause damage or injury.

Other robots
An IRC5 Compact controller used with other robots than IRB 120 has no brake
release button, only a blanking plug. The brake release button is located on the
robot.

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2 Installation and commissioning
[Link] Connectors on the controller

2.6 Connections

2.6.1 Connectors on the IRC5 Compact controller

[Link] Connectors on the controller

General
The following section describes the connectors on the front panel of the IRC5
Compact controller.

CAUTION

Always inspect the connector for dirt or damage before connecting it to the
controller. Clean or replace any damaged parts.

Connectors
The following details the connection interface on the IRC5 Compact.

xx1400001372

Description
A XS.4 FlexPendant connection

Continues on next page

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 2 Installation and commissioning
[Link] Connectors on the controller
Continued

Description
B XS.1 Robot power connection
C XS.41 Additional axes SMB connection
D XS.2 Robot SMB connection
E XP.0 Mains connection

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2 Installation and commissioning
[Link] Connecting a FlexPendant

[Link] Connecting a FlexPendant

Location of FlexPendant connector

The FlexPendant connector on the Compact Controller is located on the front of
the controller.

CAUTION

Always inspect the connector for dirt or damage before connecting it to the
controller. Clean or replace any damaged parts.

xx1400001371

A FlexPendant connector

Connecting a FlexPendant

Action Information
1 Locate the FlexPendant socket connector The controller must be in manual mode.
on the controller or operator’s panel.
2 Plug in the FlexPendant cable connector.
3 Screw the connector lock ring firmly by
turning it clockwise.

Continues on next page

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 2 Installation and commissioning
[Link] Connecting a FlexPendant
Continued

Handling the FlexPendant cables

FlexPendant cables are allowed to be rolled up by hand with a minimum bending
radius of 10 times the cable diameter. This also applies to the extension cable. For
example, if the cable is 9.5 mm then it is allowed to roll it with a radius of 95 mm.
Extension cables are not allowed to be used in chains.

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2 Installation and commissioning
[Link] Connectors on the computer unit

[Link] Connectors on the computer unit

Overview of the computer unit

The following illustration shows an overview of the computer unit.

xx1300000608

X1 Power supply
X2 (yellow) Service (connection of PC).
X3 (green) LAN1 (connection of FlexPendant).
X4 LAN2 (connection of Ethernet based options).
X5 LAN3 (connection of Ethernet based options).
X6 WAN (connection to factory WAN).
X7 (blue) Panel unit
X9 (red) Axis computer
X10, X11 USB ports (4 ports)

Note

It is not supported to connect multiple ports of the main computer (X2 - X6) to
the same external switch, unless static VLAN isolation is applied on the external
switch.

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

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 2 Installation and commissioning
[Link] Connectors on the computer unit
Continued

The service port is configured with a fixed IP-address, which is the same for all
controllers and cannot be changed, and has a DHCP server that automatically
assigns an IP-address to the connected PC.

Note

For more information about connecting a PC to the service port, see section
Working online in Operating manual - RobotStudio.

WAN port
The WAN port is a public network interface to the controller, typically connected
to the factory network with a public IP address provided by the network
administrator.
The WAN port can be configured with fixed IP-address, or DCHP, from the Boot
application on the FlexPendant. By default the IP-address is blank.
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:
• [Link] - 255
• [Link] - 255
• [Link] - 255
• [Link] - 255
• [Link] - 255
• [Link] - 255
The WAN port cannot be on a subnet which overlaps with any of the above
reserved IP-addresses. If a subnet mask in the class B range has to be used,
then a private address of class B must be used to avoid any overlapping. Please
contact your local network administrator regarding network overlapping.
See the section about topic Communication in Technical reference
manual - System parameters.

Note

For more information about connecting a PC to the WAN port, see section Working
online in Operating manual - RobotStudio.

LAN ports
The LAN 1 port is dedicated for connecting the FlexPendant.
The LAN 2 and LAN 3 ports are intended for connecting network based process
equipment to the controller. For example field buses, cameras, and welding
equipment.

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[Link] 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. The isolated LAN 3 network has the same address limitations as the
WAN network.

Note

The isolated LAN 3 cannot be used to connect to any HMI device (RobotStudio,
Robot Web Services, or PC SDK client) since it does not support the protocol
needed for communication.

Robot Controller

Private Isolated Public

LAN 3

Service LAN 1 LAN 2 LAN 3 WAN

xx1500000393

An alternative configuration is that LAN 3 is part of the private network. The ports
Service, LAN 1, LAN 2, and LAN 3 then belong to the same network and act just
as different ports on the same switch. This is configured by changing the system
parameter Interface, in topic Communication and type Static VLAN, from "LAN 3"
to "LAN". See Technical reference manual - System parameters.

Robot Controller

Private Public

Service LAN 1 LAN 2 LAN 3 WAN

xx1500000394

Note

For more information and examples of connecting to different networks, see

Application manual - EtherNet/IP Scanner/Adapter or Application
manual - PROFINET Controller/Device.

USB ports
The USB ports are intended for connecting USB memory devices.

Note

It is recommended to use the USB ports USB 1 and USB 2 on the X10 connector
for connecting USB memory devices.
The USB ports on the X11 connector are intended for internal use.

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[Link] Connecting a serial channel to the controller

[Link] Connecting a serial channel to the controller

General
The serial channel is an option. To be able to connect a serial channel to the
controller, the main computer needs to be equipped with the expansion board
DSQC1003.
The expansion board has one RS232 serial channel, COM1, which can be used to
communicate with process equipment.
The expansion board also enables the connection of a fieldbus adapter. For more
information on how to connect a fieldbus adapter, see Definition of fieldbuses,
IRC5 on page 93.

Location
The serial channel connector is located on the expansion board in the computer
unit as shown below.

A B

xx1300000610

A COM1
B CONSOLE

Note

The CONSOLE connector is used for debugging purposes only.

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[Link] Connecting a serial channel to the controller
Continued

Conversion of the RS232 channel

The RS232 channel can be converted to RS422 full duplex with an optional adapter,
DSQC 615.
The RS422 enables a more reliable point to point communication (differential) over
longer distances, from RS232 = 15m to RS422 = 120m.
Action Info/Illustration
1 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

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2.6.2 Connecting cables to the controller

2.6.2 Connecting cables to the controller

General
A good and proper electrical installation of the robot system is necessary to ensure
the best performance and prolong the lifetime of the whole robot system.
This section includes important information on how to connect cables and signals
to the controller.

Signal classes
Different rules apply to the different classes when selecting and laying cables.
Signals from different classes must not be mixed.
Signal class Description
Power signals Supplies external motors and brakes.
Class 4 (noisy) Applies to the cables associated with the power inputs and outputs
of variable speed drives. Cables carrying strongly interfering signals
such as motor cables, DC-link load sharing, unsuppressed inductive
loads, DC motors, welding equipment, etc.
Control signals Digital operating and data signals (digital I/O, protective stop, etc.).
Class 3 (slightly Applies to cables carrying slightly interfering signals: AC power
noisy) supply (<1 kV), DC power (24 V), power to equipment with RFI/EMI
filters, control circuits with resistive or suppressed inductive loads
(such as contactors and solenoids), direct-on-line induction motors,
etc.
Measurement signals Analog measurement and control signals (resolver and analog I/O).
Class 2 (slightly sens- This class covers ordinary analogue signals such as analogue sig-
itive) nals (4-20 mA, 0-10V, or signals below 1 MHz), low-speed digital
signals (RS232, RS485), digital (on/off) signals, limit switches, en-
coders, etc.
Data communication Gateway (fieldbus) connection, computer link.
signals Applies to cables carrying very sensitive signals. Signals with a full-
Class 1 (sensitive) scale range less than 1 V or 1 mA, and/or a source impedance >1
kOhm, and/or a signal frequency >1 Mhz. For example high-speed
digital communication (Ethernet), thermocouples, thermistors, strain
gauges and flowmeters.

Selecting cables
All cables laid in the control cabinet must be capable of withstanding 70°C. In
addition, the following rules apply to the cables of certain signal classes:
Signal class Cable type
Power signals Shielded cable with an area of at least 0.75 mm² or AWG 18.
Control signals Shielded cable.
Measurement signals Shielded cable with twisted pair conductors.
Data communication Shielded cable with twisted pair conductors. A specific cable
signals should be used for field bus connections and Ethernet, according
to the standard specification of the respective bus.

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2.6.2 Connecting cables to the controller
Continued

Note

Any local standards and regulations concerning insulation and area must always
be complied with.

Route the cables

Routing of cables shall be done in a professional way.
• Cables of different classes, such as signal cables and power cables, must
not be routed together as the power cables may introduce noise in the signal
cables. The greater the separation distance, the lesser the risk for interference
between the cables.
• Robot controller mains supply input cable and robot power cable should be
separated even though they belong to the same class.
• If crossing cables from different classes, cables should cross at an angle
close to 90 degrees.
• All external cables that are to be connected inside the controller must be
shielded in the chassis before entering the cabinet.
Separation distances can be reduced if e.g. dividers are used between cables
classes. Manufacturers of cable duct systems can provide information on how
reduced separation distances can be achieved using their specific products.
Signal class Cable type
Power signals • These signals generate a lot of interference and must be
laid separate from control, measurement, and communica-
tion signals.
• The shielding must be connected to a paint-free part of the
panel chassis of the cabinet at both ends of the cable. Any
unshielded cable must be as short as possible.
• The manipulator power cables are routed on the floor and
along the left side of the controller cabinet.
• Cables should not be wound up like coils. This could cause
an magnetic field disturbing the signals. There will also be
a risk of overheating depending on the load.
Control signals • These signals are very sensitive to interference. To protect
these signals they should not be laid along with the power
Measurement signals signals.
Data communication • In the cable, each signal must be twisted with a neutral wire.
signals • The shielding must be connected directly to the chassis at
both ends of the cable.

Shielding cables
When peripheral devices are connected to the robot system, a shielded cable is
necessary to reduce coupling of the inner cable conductors to the environment
they pass through.

Shielding cable requirements

• The best method for shielding is to ground the shield at both ends of the
cable, provided the ends grounding are at the same potential.
• If the grounding points have different electric potentials - grounding both
ends will create a ground loop allowing unwanted current to flow in the shield.

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2.6.2 Connecting cables to the controller
Continued

In such cases one end grounding may be used. The grounding point should
then be at the robot controller side.
• Cables carrying analog low-level signals is another exception where the
shield should be grounded at only one end.
• Most data network and field bus types have defined grounding topologies.
If such grounding schemes exist, they should be followed.
• In complex interference environments, two-layer shielding may be required.
The inner shield should be grounded at the controller side only end and the
outer shield should be grounded at both ends. The optimum shielding is a
combination of foil and braid screens.
• The best connection is one in which the shielding is extended up to and
makes a solid 360° connection (shown below) with the ground plane or
chassis.

Shielding example
The below example shows the shielding of a d-type connector:

xx1700001320

A A dimpled connector body makes multiple bonds to the mating connector

body all around its periphery, 360° bonding.
B Metal, or metallized, back shell makes 360° bond to the connector body.
C The cable shield is exposed and 360° clamped to the back shell. A tight fit
is a must.
Many other 360° bonding methods and types of 360° shielded connectors are also
acceptable.

Shield pigtail termination

Shield pigtail termination, as shown below, shall be avoided. If a pigtail connection
cannot be avoided, make it as short as possible.

xx1700001321

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2.6.2 Connecting cables to the controller
Continued

Ground and screen connections

The task of the grounding system is twofold - protective and functional. The primary
task is to serve as protective earth (PE) for personal and equipment safety. The
secondary task is to serve as a return path for common mode current.
For further information refer to EN 60204-1 and UL 1740.

Grounding requirements
The controller cabinet ground must come from the mains power supply PE.
• The cross-sectional area of each grounding (PE) conductor must be not less
than 2 mm 2 copper (AWG14) in the IRC5 Compact controller, and not less
than 10 mm 2 copper (AWG7) in the manipulator.
• The grounding cable color shall be green-yellow.
• The ground for the controller cabinet, robot manipulator and peripheral
devices must be the same, preferably an equipotential ground grid (mesh).
• Ground connection points must have stable inter-metallic bonding, like screw
fixation. Paint, dirt, rust, and other insulating material must be removed from
the contacting surfaces.
For requirements on the marking of the supply ground connection inside the control
cabinet refer to UL 508C. For further details on how grounding systems should be
designed refer to IEC 61000-5-2. For details of cross-sectional area of PE refer to
IEC 60204-1.

Grounding installation
For information on how to install the ground for the IRC5 Compact controller cabinet,
see Grounding on page 72.
For information on how to install the ground for the manipulator, see the
corresponding product manual.

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2.6.2 Connecting cables to the controller
Continued

Examples
The following figure shows 2 examples on how the ground and the signal cable
screens can be connected:

Control cabinet External unit

Example 1

Example 2

xx1200000960

Example 1:
• Where a good ground is available on all units, the best shielding is obtained
by grounding all screens at both ends on all units.
Example 2:
• If the cable is terminated where a good ground is not available a noise
suppression capacitor can be used. The screens of the 2 cables must be
connected as shown in the figure, but not connected to the chassis of the
unit.

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2.6.2 Connecting cables to the controller
Continued

Interference elimination
Internal relay coils and other units that can generate interference inside the control
cabinet are neutralized. External relay coils, solenoids and other units must be
clamped in a similar way. The illustration below shows how this can be done.
Note that the turn-off time for DC relays increases after neutralization, especially
if a diode is connected across the coil. Varistors give shorter turn-off times.
Neutralizing the coils lengthens the life of the switches that control them.

+24 V DC 0V

1)

2)

+24 V AC/DC 0V

3)

xx1200000961

1 The diode should be dimensioned for the same current as the relay coil, and
a voltage of twice the supply voltage.
2 The varistor should be dimensioned for the same energy as the relay coil,
and a voltage of twice the supply voltage.
3 When AC voltage is used, the components needs to be dimensioned for >500
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).

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2.6.3 Power supply system requirements

2.6.3 Power supply system requirements

Definition of the power supply system

IEC 60364 defines three different types of mains grounding using the two-letter
codes. These are TN, TT, and IT.
First letter Type of ground connection
T Direct connection of one point to ground.
I Not connected to ground or connected to ground via a high impedance.

Second letter Connection between ground and the device being supplied
T Direct connection of one point to ground.
N Direct connection to neutral at the origin of installation, which is connec-
ted to the ground

In the following section the transformer configuration refers to the transformer

secondary side. Configuration of the transformer primary side is not discussed in
this context.

Recommended power supply systems

The following systems are recommended by ABB:
TN−S system TN−C system
PE and N are separate conductors that are A combined PEN conductor is used as both
connected together only near the transformer. a PE and an N conductor.
L1 L1

L2 L2

L3 L3

N PEN

PE

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
grounding path resistance between ground voltage variations between any line and PE
1 and 2 shall not exceed 0.1 Ohm, for more should not exceed ±10% of the nominal line
information refer to UL1740. voltage, for more information refer to EN
50160.

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2.6.3 Power supply system requirements
Continued

TT system (separate ground rods) Resistance grounded secondary system

L1 L1

L2 L2

L3 L3

N N

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. Inher- undefined and may cause damage to both
ent phase imbalances with respect to ground drive system and mains line filter (if installed).
would put the drive system and mains line
filter (if installed) under unacceptable stress.
L1

L2

L3

xx1700001316
xx1700001317

xx1700001315

xx1700001314

Isolation transformer
A three-phase isolation transformer between the mains supply and the control
cabinet is required for any of the below conditions:
• Not allowed power supply system used, as mentioned in Not allowed power
supply systems on page 68.
• When the mains supply is shared with a pressing machine, frequency
converter, or other large industry equipment that may cause the power supply
characteristics out of standard limits. To some extent, isolation transformers
will filter out harmonics, spikes and surges.

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2.6.3 Power supply system requirements
Continued

For further information refer to regional power supply standards.

Allowed isolation transformer types

The following isolation transformer types are allowed by ABB:
Delta-Wye isolation transformer (△/Y) Wye-Wye isolation transformer (Y /Y)

xx1700001318 xx1700001319

A Primary/input
B Secondary/output

Mains line filter

A mains line filter is included in the IRC5 Compact 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.

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2.6.4 Connecting power supply

2.6.4 Connecting power supply

Note

How to manufacture a cable with connector is described in section Fitting the

connector on page 73.

CAUTION

Always inspect the connector for dirt or damage before connecting it to the
controller. Clean or replace any damaged parts.

Location
The following illustration shows the location of the power input connector on the
front panel of the controller.

xx1400001372

Description
A XS.4 FlexPendant connection
B XS.1 Robot power connection
C XS.41 Additional axes SMB connection

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2.6.4 Connecting power supply
Continued

Description
D XS.2 Robot SMB connection
E XP.0 Mains connection

Required equipment

Equipment Note
Power supply cable (single phase)
External circuit breaker 16A
External earth fault protection at control cables 3 -15m 30mA
External earth fault protection at control cables >15m 300mA
Circuit diagram See Circuit diagrams on page 221.

Connecting power to the controller

The following procedure describes how to connect the mains power to the controller.
Action
1 Connect the power cable from the power supply to connector XP0 on the front panel
of the controller.

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2.6.5 Grounding

2.6.5 Grounding

Location

Note

The whole cabinet ground is connected to the [Link] point.

2 1

A
5

xx1700000507

Description
A XP0.1 Power lline
B [Link] Grounding
C XP0.2 Zero line

Required equipment

Equipment Note
Mains connection cable (single phase)
Circuit diagram See Circuit diagrams on page 221.

Connecting ground controller

The following procedure describes how to connect the mains power to the controller.
Action
1 Connect single-phase power supply and PE wire to the XP0 connector.

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2.6.6 Fitting the connector

2.6.6 Fitting the connector

General
This section describes how to manufacture a cable for connecting the mains power
to the controller.

Specifications
The following describes the cable and fuse requirements for the mains power
connection to the IRC5 Compact controller.
Component Description
Cable type Flexible oil resistant rubber
Cable area 3 x 2.5 mm 2
Fuse Delay action fuse 16A

Included parts
The following parts are included in the delivery.
Part Recommended supplier Order number Quantity
Hood Harting, 19 20 003 1640 3HAC051426-001 1
Female insert Harting, 09 12 005 2733 3HAC037697-001 1
Cable gland Harting, 19 00 000 5184 3HAC034913-001 1

Procedure
Use the following procedure to fit the connectors.
Action Note/illustration
1 Select a suitable single phase cable and earth cable, See previous specifications.
and cut it to desired length.
2 Fit the cable through the cable gland and hood.

xx0900000365

• A: hood
• B: female insert
• C: cable gland

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2.6.6 Fitting the connector
Continued

Action Note/illustration
3 Connect the wires according to the illustration. Use a
screwdriver to make the contact tight.

xx0900000366

For single phase:

• X0.1 - power line
• X0.2 - zero line
• [Link] - earth wire
4 Assemble the connector by fitting the hood and the
female connector, and tighten the screws.

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2.6.7 Descriptions for connectors XS7 - XS17

2.6.7 Descriptions for connectors XS7 - XS17

XS7, XS8 and XS9 Safety

XS7 XS8 XS9

xx1500002927

These connectors is internally connected with safety board.

It contains the following signals:
• Auto stop
• General stop
• External emergency stop PB
• External supply
• External PTC
For connection details, see circuit diagram for IRC5 Compact, see Circuit diagrams
on page 221.

Note

Safety male connectors are delivered with Compact controller. The bridge
connector can be bought from ABB (3HAC051190-001). If it is bought from the
manufacturer, see Circuit diagrams on page 221 for connection details.

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2.6.7 Descriptions for connectors XS7 - XS17
Continued

XS12, XS13, XS14 and XS15 I/O

XS12
XS13
XS14
XS15

xx1500002926

These connectors are internally connected with the I/O unit (DSQC 651 or DSQC
652).
It contains 8 digital input and output signals, 8 analog output signals of DSQC 651.
It contains 16 digital input and output signals of DSQC 652.
It contains 24V, 0V for outputs and 0V for input of DSQC 651 or DSQC 652.
For connection details, see circuit diagram for IRC5 Compact, see Circuit diagrams
on page 221.

XS16 Power Supply

XS16

xx1500002928

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2.6.7 Descriptions for connectors XS7 - XS17
Continued

This connector is internally connected with I/O unit (DSQC 652) and power
distribution unit.
It contains the following signals:
• 24V power supply

Note

Total customer usage for 24V power supply from XS16 must not exceed 6A.
For connection details, see circuit diagram for IRC5 Compact controller.

Note

Power male connector are delivered with Compact controller. The power
connector is included in the same cable as DeviceNet connector
(3HAC054250-001). The bridge connector is a part of the cable 3HAC049564-001.

XS17 DeviceNet

XS17

xx1500002929

This connector is internally connected with DeviceNet - master bus.

It contains a DeviceNet signal.
For connection details, see circuit diagram for IRC5 Compact controller.

Note

DeviceNet male connectors are delivered with Compact controller. The DeviceNet
connector is included in the same cable as power connector (3HAC054250-001).
The bridge connector is a part of the cable 3HAC049564-001.

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2.6.7 Descriptions for connectors XS7 - XS17
Continued

XS18 Profibus

XS18

xx1500002972

This connector is internally connected with Profibus - master bus.

It contains a Profibus signal.
For connection details, see circuit diagram for IRC5 Compact controller.

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2.6.8 The MOTORS ON/MOTORS OFF circuit

2.6.8 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, and ES.

A E

B C C
D

G F
U

H &
P S
R T
K

M N

xx1600000280

A ES (emergency stop)
B LS (Limit switch)
C Solid state switches
D Contactor
E Mains
F Drive unit
G Second chain interlock
H GS (general mode safeguarded space stop)
K AS (Automatic mode safeguarded space stop)
L ED (FlexPendant three-position enabling device)
M Manual mode
N Automatic mode
O Operating mode selector
P RUN
R EN1
S EN2
T Motor

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2.6.8 The MOTORS ON/MOTORS OFF circuit
Continued

U SS (Input from, for example, SafeMove board)

Function of the MOTORS ON/MOTORS OFF circuit

The circuit monitors all safety related equipment and switches. If any of the switches
are opened, the MOTORS ON/MOTORS OFF circuit switches the power to Motors
Off.
As long as the two chains not are in an identical state, the robot will remain in
MOTORS OFF mode.

Connection of safety chains

The diagram below shows the dual channel safety chain.
The supply from internal 24V and 0 V is displayed. For external supply of GS and
AS check the circuit diagram.

X15.4
Opto SS1
X15.2 isol.

Opto GS1
isol.

Opto AS1
isol.

X15.5
Opto SS2
X15.3 isol.

Terminal Location
GS2
X5 A21

X15 A21
AS2

xx1600000281

Technical data per chain

Limit switch Load: 300 mV
Max. voltage drop: 1 V

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2.6.8 The MOTORS ON/MOTORS OFF circuit
Continued

Technical data per chain

External connectors Load: 10 mA
Max. voltage drop: 4 V
GS/AS load at 24 V 25 mA
GS/AS closed "1" >18 V
GS/AS open "0" <5V
External supply of GS/AS/SS Max. + 35 VDC
Min. - 35 VDC
GS/AS Filter time 2.0 ms 1 )
Max. potential in relation to the 300 V
cabinet earthing and other signal
groups.
Signal class Control signals

1) When connecting e.g. a Safety PLC to a safety stop, make sure that the safety
check pulses do not exceed 2.0 ms, otherwise a safety relay must be connected
in between. See illustration below.

Safety PLC
IRC5 Compact

Safety board (A21)

Safety relay
Contact X9

X9.30 (AS1+)
X9.31 (24 V)

X9.22 (AS2-)
X9.20 (0 V)

en0900000482

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2.6.8 The MOTORS ON/MOTORS OFF circuit
Continued

Connection of ES1/ES2 on panel unit

The diagram below shows the terminals for the emergency circuits.
The supply from internal 24V (X1:2/X2:6) and 0V (X1:6/X2:2) is displayed. For an
ext. supply, X1:1 / X2:5 is connected to ext. 24V, and X1:5 / X2:1 is connected to
ext. 0V.
A

24V 0V
B C D
X1:2 X1:1
X1:7

X1:8
X1:6 X1:5
24V

X1:4
E
24V
X1:2
X1:3
G
0V 24V
F
B C D
X2:2 X2:1
X2:7

X2:8
X2:6 X2:5
0V

X2:4
H
0V
X2:2

X2:3
J
xx1000001009

A Internal
B Ext stop
C FlexPendant
D Cabinet
E ES1 internal
F Run chain 1 top
G Internal
H ES2 internal

Continues on next page

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 2 Installation and commissioning
2.6.8 The MOTORS ON/MOTORS OFF circuit
Continued

J Run chain 2 top

Technical data
External supply of ES relay 24 VDC ± 10% between terminals X1:3,
7 and X2:7, 3 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

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2 Installation and commissioning
2.6.9 Programmable stop functions

2.6.9 Programmable stop functions

Stopping functions
There are different methods to stop the robot, in addition to manually initiated
stops.
• Stop with system input signals
• Stop with RAPID instructions
• Other stops

Stop with system input signals

In the control system, it is possible to define system input signals to be set/reset
through different interactions, for example, through I/O signals. See Application
manual - Controller software IRC5.
The RAPID program cannot be started when any of the system input signals is
high.
Pre-defined system input Description
Stop The RAPID program execution is stopped, and the manipulator
is stopped on path with no deviation. This stop is similar to a
normal program stop using stop button on the FlexPendant.
SoftStop This is a faster stop of the manipulator than Stop. This stop is
more stressing for the mechanics than normal stop, therefore
there might be a minor deviation on path.
QuickStop This is a faster stop of the manipulator than Stop and SoftStop.
This stop is more stressing for the mechanics than normal stop
or SoftStop, therefore there might be a deviation on path.
Stop at End of Cycle Stops the RAPID program when the complete program is ex-
ecuted, that means when the last instruction in the main routine
has been completed.
Stop at End of Instruction Stops program execution after the current instruction is com-
pleted.

All of these stops are performed without using the brakes, and the power is never
disconnected. The program execution can be continued directly, for example by
activating a start signal if the stop signal is set low.

Note

Only safety rated input signals are allowed to be used for safety.

Continues on next page

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2.6.9 Programmable stop functions
Continued

Stop with RAPID instructions

There are several RAPID instructions available that stops the robot.
Instruction Description Arguments
SystemStopAction Stops all robots in all tasks imme- \Stop: similar to a normal pro-
diately. gram stop with stop button.
\StopBlock: as above, but to re-
start the PP has to be moved.
\Halt: this is like a category 0
stop, i.e. it will result in motors off
state, stop of program execution
and robot movements in all motion
tasks. The Motors on button must
be pressed before the program
execution can be restarted.
Stop The current move instruction will \NoRegain: the robot will not re-
be finished before the robot stops. turn to the stop point when restar-
A restart will continue the program ted, e.g. after having been jogged
execution. away.
\AllMoveTasks: all robots will be
stopped.
StopMove The current move instruction will \Quick: the stop will be a soft
be stopped immediately as a nor- stop on path, as described for
mal program stop but the program system input SoftStop, otherwise
execution will continue with the similar to a normal program stop.
next instruction. StartMove must \AllMotionTasks: all robots will
be executed to get the robot mov- be stopped.
ing again.
BREAK The current move instruction and
the program execution will be
stopped immediately as a normal
program stop. A restart will contin-
ue the program execution.
EXIT The current move instruction and
the program execution will be
stopped immediately as a normal
program stop. After stop the Pro-
gram Pointer is lost and has to be
reset to Main.
EXITCYCLE The current move instruction and
program execution will be stopped
immediately. 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

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2.6.9 Programmable stop functions
Continued

Instruction Description Arguments

SearchX Search instructions can be pro- \Stop: the robot will stop as fast
grammed with arguments to stop as possible. This stop is per-
the robot movement close to the formed by ramping down motion
point where a search hit was no- in each motor separate from each
ticed. The program execution will other, and as fast as possible.
continue with the next instruction. Since it will be without any coordin-
ation, the robot may slide off path
fairly much.
\PStop: the robot will stop like
after a normal program stop.
\SStop: the robot will stop on path
but quicker than a normal program
stop. This is similar to a system
input SoftStop.
\Sup: the robot will continue to the
ToPoint. If more than one search
hit is found, an error will be repor-
ted.

RAPID instructions are described in Technical reference manual - RAPID

Instructions, Functions and Data types.

Other unexpected stops

Type of stop Description

SysFail In the control system there is a surveillance and monitoring
function that can detect abnormal situations. In such cases a
stop will be initiated. The robot controller must be restarted.
Power fail In the control system there is a monitoring function that can
detect power failure. In such cases a stop will be initiated.
Stop at collision In the control system there is a monitoring function that can
detect collisions. In such cases a stop will be initiated.

WARNING

Special care must be taken when restarting a machine that is

stopped due to a collision. 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.

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 2 Installation and commissioning
2.6.10 Emergency stop output

2.6.10 Emergency stop output

Emergency stop output through safety relay

The safety board DSQC 400 does not have an emergency stop output. The
emergency stop output can be extended by adding one safety relay. The diagram
below shows the connection of a safety relay, type RT6 from Jokab Safety. ABB
Robotics does not offer the safety relay option. The safety relay can be purchased
from Jokab Safety or Pilz.

Note

The safety board DSQC 400E has an integrated emergency output connector
(X14), but this is only intended for functional safety module DSQC1015. It is not
recommended to connect external equipment to this connector inside the
controller. Therefore, it is recommended to use the same solution for DSQC 400E
as for DSQC 400.
For more information on the safety board, see Replacement of safety board on
page 130 and Controller system parts on page 211.

Safety relay on safety board DSQC 400

-A21
-X13
-LIM_2B / 12;7
-X12 24V FPU POWER
11;4 / -24V SYS 24V SYS 1
-LIM_2A / 12;7
Power distribution 24V PANEL
1 2
board 11;5 / -0V SYS 0V SYS -LIM_1B / 12;7
3
2 -LIM_1A / 12;7
24V PANEL

12;3 / -24V COOL 4

EXTERNAL 3
EMERGENCY 12;3 / -0V COOL
-S21.3 STOP PB 4 FPU
21 22 ES1 top XS7/X1 -X10 -209 AWG20 BU -ES FPU 1:A / 12;7
1 XS8/X2 5
11 12 ES2 top -211 AWG20 BU -ES FPU 2:A / 12;7
1 7
-212 AWG20 BU -ES FPU 2:B / 12;7

8
0V 0V -210 AWG20 BU -ES FPU 1:B / 12;7
24V Panel 2
2 24V PANEL 6
RunCh0V
RunCh+

EXTERNAL
EMERGENCY Run CH1 top
STOP OUTPUT Run CH2 top 3
-S21.3
X53 X1 X4 3 -X9
-237 AWG20 21 22
A1 S13 S14 S34 13 23 33 41 -238
3
AWG20
-233 AWG20 11 12
9
9 -234 AWG20
5
SAFETY -231 AWG20
11
RELAY -232 AWG20
6
Sep ES2:A RunCh0V -235 AWG20
12
Sep ES1:A 7 RunCh+ -236 AWG20
4
7
10
1
U U

Sep ES1:B
2 8
Sep ES2:B
8
ES2 bottom
JUMPER
JUMPER

ES1 bottom 5
5 -X11
0V
24V Panel 6
1
6
2
AWG24 -24V_Sig.ref. / 12;8
EXTERNAL BU
24V PANEL 3 -RS485+ / 12;8
SUPPLY WHBU
4 -RS485- / 12;8
A2 S23 S24 S44 14 24 34 42 0V 5
6
WHBN -0V_Sig.ref. / 12;8
ES1:int 7
-RunCh_0V
-RunCh+

-RCH2
-RCH1

4
8
ES2:int MAIN
4 COMPUTER
ES1 ES2
12;6 /
12;6 /
12;6 /
12;6 /

xx1100000556

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2 Installation and commissioning
2.7 Opening the IRC5 Compact controller

2.7 Opening the IRC5 Compact controller

Removing the controller cover

Action Info/illustration
1
DANGER

Before any work inside the cabinet,

read the safety information in section
Electrical safety on page 32.

2 Remove the attachment screws on

the cover.

xx1400001364

3 Push the cover towards the back of

controller to release it from the bend
of the front panel, and then pull up-
wards to remove it.

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 2 Installation and commissioning
2.8.1 Drive functions, general

2.8 Drive system

2.8.1 Drive functions, general

General
The robot is powered by power electronics found in the IRC5 Compact controller.

Location of drive unit

xx1400001373

A Main Drive Unit

Replacing drive system parts

How to replace the drive unit is described in section Replacement of drive unit on
page 166.

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2.9.1 Memory functions

2.9 Memory functions

2.9.1 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 Replacement
of SD-card memory in computer unit on page 163.

Note

Only use SD-card memory supplied by ABB.

CAUTION

Reformatting the SD-card or modifying the disk partition can cause irreparable
boot-up problems.

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 2 Installation and commissioning
2.9.2 Connecting a USB memory

2.9.2 Connecting a USB memory

Handling USB
Handling of USB memory is described in Operating manual - IRC5 with FlexPendant.

Location on FlexPendant
The location of the USB port on the FlexPendant is shown by the following
illustration:

A
xx0900000022

A USB port (located behind rubber cover)

Continues on next page

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2.9.2 Connecting a USB memory
Continued

Location on the controller

The location of the USB ports on the IRC5 Compact controller is shown by the
following illustration:

xx1400001376

A USB port 1 - 4

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2.10.1 Definition of fieldbuses, IRC5

2.10 I/O system

2.10.1 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.

B
xx1600000536

A Slot for PCIexpress boards

B Slot for safety module (option SafeMove Pro or SafeMove Basic)

The following master/slave boards are available:

Description Art. no. Type designation
PROFIBUS Master PCIexpress 3HAC044872-001 DSQC1005
DeviceNet Master/Slave PCIexpress 3HAC043383-001 DSQC1006

Continues on next page

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2.10.1 Definition of fieldbuses, IRC5
Continued

Expansion board for fieldbus adapters

An expansion board needs to be installed to be able to fit a fieldbus adapter. On
top of the main computer unit, there is one slot available for installing the expansion
board.
The expansion board is also equipped with a serial channel. For more information
on how to connect to the serial channel, see Connecting a serial channel to the
controller on page 59.

xx1300000605

A Assembled expansion board for fieldbus adapters, without adapter.

Description Art. no. Type designation

AnybusCC / RS232 expansion 3HAC046408-001 DSQC1003
board

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2.10.1 Definition of fieldbuses, IRC5
Continued

Fieldbus adapters
The fieldbus adapters are inserted into the expansion board on top of the main
computer unit. There is one slot available for installing a fieldbus adapter.

xx1300000604

A Slot for AnybusCC fieldbus adapters

Following fieldbus adapters are available:

Description Art. no. Type designation
AnybusCC DeviceNet slave 3HAC045973-001 DSQC1004
AnybusCC PROFIBUS slave 3HAC026840-001 DSQC 667
AnybusCC Ethernet/IP slave 3HAC027652-014 DSQC 669
AnybusCC PROFINET slave 3HAC031670-001 DSQC 688

References
For more information on how to install and configure the fieldbuses, see the
respective fieldbus manual:
Manual title Art. no.
Application manual - DeviceNet Master/Slave 3HAC050992-001
Application manual - DeviceNet Anybus Slave 3HAC050993-001
Application manual - EtherNet/IP Anybus Adapter 3HAC050997-001
Application manual - EtherNet/IP Scanner/Adapter 3HAC050998-001
Application manual - PROFIBUS Anybus Device 3HAC050965-001
Application manual - PROFIBUS Controller 3HAC050966-001
Application manual - PROFIenergy Device 3HAC050967-001

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2.10.1 Definition of fieldbuses, IRC5
Continued

Manual title Art. no.

Application manual - PROFINET Anybus Device 3HAC050968-001
Application manual - PROFINET Controller/Device 3HAC065546-001

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 2 Installation and commissioning
2.10.2 DeviceNet I/O units

2.10.2 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.

Standard configuration
In the standard form, no fieldbus is mounted to the controller.
It is possible to connect any type of DeviceNet compliant I/O unit on the DeviceNet
- master bus. All I/O units should comply with the DeviceNet standard and be
conformance tested by ODVA.

DeviceNet I/O units and parts

The table below specifies the DeviceNet I/O units:
Description Note
Digital I/O DSQC 652

See Spare parts on page 211 for the spare part numbers.

Encoder interface units

The table below specifies the encoder interface units:
Description Art. no. Note
Encoder interface unit for conveyor 3HNE 01586-1 DSQC 377B
tracking

Further information
The table below gives references to additional information:
Information: Found in:
How to install the DeviceNet I/O Fit the expansion board and/or field bus adapter ac-
units mechanically and electrically. cording to Replacement of expansion board in the
computer unit on page 152 and/or Replacement of
fieldbus adapter in the computer unit on page 155.
Allowed configurations of Devi- Technical reference manual - System parameters
ceNet I/O units and how to setup
the configurations.
How to install the DeviceNet I/O unit The application manual for the different I/O buses re-
software related in a new system. spectively, see listing in Definition of fieldbuses, IRC5
on page 93.
Detailed descriptions of all available The application manual for the different I/O buses re-
DeviceNet I/O units. spectively, see listing in Definition of fieldbuses, IRC5
on page 93.

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2 Installation and commissioning
2.10.3 Conveyor tracking module
RobotWare - OS

2.10.3 Conveyor tracking module

General
The conveyor tracking module, DSQC 2000 CTM-01, is a network based conveyor
interface that provides connections for 4 encoders and 8 cameras. The camera
connections can also be used for other sensor types, for example photocells. The
module uses network communication to share conveyor speed and position data
with one or more robot controllers.

xx1800000941

Encoder interface units

The table below specifies the encoder interface units:
Description Art. no. Note
DSQC2000 CTM-01 3HNA027579-001 Conveyor tracking
module
CONNECTOR KIT - DSQC2000 3HNA029345-001 Connector kit

Note

The connector kit in-

cludes contacts for 2
encoders and 4 camer-
as.
Two connector kits
are needed to handle
additional encoders
and cameras.

Continues on next page

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2.10.3 Conveyor tracking module
RobotWare - OS
Continued

Further information
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

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2 Installation and commissioning
2.11.1 Installation of external operator's panel

2.11 Installation of add-ons

2.11.1 Installation of external operator's panel

Location
An external operator's panel may be fitted in a separate wall cabinet as shown in
the illustration below.

D
C
E

B
F

A
G

I H
xx1000000954

A Wall cabinet
B Front panel
C Blanking plug for FlexPendant
D Blanking plug for actuator red
E Emergency stop button
F Motor ON button
G Mode switch
H External Operator's panel harness
I FlexPendant connector

Required equipment

Equipment Art. no. Note

Wall cabinet IRC5 3HAC038671-001
External Operator's panel 3HAC065947-001 7m
cable 3HAC065947-004 15 m
3HAC065947-005 30 m
Circuit diagram See Circuit diagrams on
page 221.

Continues on next page

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2.11.1 Installation of external operator's panel
Continued

Procedure
The procedure below details how to install the external control panel.
Action Info/illustration
1
DANGER

Before any work inside the cabinet, read

the safety information in section Electrical
safety on page 32.

2 Remove the cover of the cabinet. See Opening the IRC5 Compact controller
on page 88.
3 Remove the two attachment screws for the
safety board unit and gently pull it out a
little bit.
4 Remove the contactor unit (contactors at-
tached with plate) attachment screws and
move the unit leftwards a little bit.
5 Disconnect signal cabling from the safety
board.
Connectors: X9

• A21.X6
X6
• A21.X9

xx1500000114

6 Detach the Emergency stop button, Motor

on button and Mode switch together with
their cabling on the controller. Mount these
buttons and switch on the external operat-
or's panel and strap the cabling to the exist-
ing cable strapping behind the front panel.
7 Connect the round connector from the ex-
ternal operator's panel harness to XS4 on
the controller.
8 Fit the cable from the external operator's
panel harness to the controller through the
hole for Emergency stop button and tighten
the cable gland.

xx1000000956

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2.11.1 Installation of external operator's panel
Continued

Action Info/illustration
9 Cover the holes for Motor on button and
Mode switch on the controller with a
blanking plug.
10 Connect the earth cable to the ground ter- A
minal inside the cabinet.

xx1400002803

• A: ground terminal
11 Connect the signal connectors Ext.A21.X6
and Ext.A21.X9 to the connector X6 and X9
on the safety board.
12 Strap the cables and secure the attach-
ments screws for contactor unit and safety
board unit.
13 Fit the external operator's panel harness to
the wall cabinet with four attachment
screws.
14 Connect the connectors and earth cable
inside the wall cabinet.
15 Mount the front panel of the external oper-
ator's panel on the wall cabinet with four
attachment screws.

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2.11.2 Installation of external enabling device

2.11.2 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.

Connecting the external enabling device

The external enabling device must be connected to the safety board connector X6
pin 7-10 as shown in the figure below.

IRC5

Safety board (A21)

Connector X6

External enabling
X6.7 (EN1_1A)
device

X6.9 (EN2_1B)

X6.10 (EN2_1A)

X6.8 (EN1_1B)

xx1600000181

The enabling device chain is enabled if X6 pin 7 is short circuited with X6 pin 8 at
the same time as X6 pin 9 is short circuited with X6 pin 10.

Requirement on the external enabling device

The external enabling device connected to IRC5 must have the following
characteristics:
• Redundant channels.
• Three-position enabling device. When the enabling device is pressed to the
center position the enabling device chain must be enabled. When the enabling
device is released or pressed to third position, the enabling device chain
must be disabled.
• The enabling device must have a B10 value of at least 100000 cycles (less
than 10% chance of failure before 100000 cycles).
• The mean time to dangerous failure (MTTFd) of the external enabling device
must be high enough to ensure that the external enabling device together

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2 Installation and commissioning
2.11.2 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:
• MTTFd for IRC5 enabling device chain is 80 years.
• IRC5’s enabling device chain’s calculated average probability of dangerous
failure per hour (PFHd) is 6.62x10E-08.
• IRC5’s enabling device chain’s design and structure is category 3.
• IRC5’s enabling device chain’s Diagnostic Coverage is medium (90% < DCavg
< 99%).
• The Common Cause Failure (CCF) is met according to the standard
requirements.

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2.11.3 Installation of conveyor tracking module
RobotWare - OS

2.11.3 Installation of conveyor tracking module

Location
The conveyor tracking module must be powered by a 24V power supply and
connected to the Ethernet.

B
xx1800002638

A X1, Power inlet 24VDC

B X20, Optional camera power inlet 24VDC
C X7 WAN, Ethernet connection

Required equipment

Equipment Article number Note

DSQC 2000 CTM-01 3HNA027579-001
CONNECTOR KIT - DSQC 2000 3HNA029345-001
Application manual - Conveyor 3HAC050991-001
tracking
Standard toolkit See Standard toolkit, IRC5
on page 209.

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2.11.3 Installation of conveyor tracking module
RobotWare - OS
Continued

Equipment Article number Note

Circuit diagram - IRC5 Compact 3HAC049406-003

Note

The connector kit includes contacts for 2 encoders and 4 cameras. Two connector
kits are needed to handle additional encoders and cameras.

Fitting
The procedure below details how to fit the units.
Action Note/Illustration
1
DANGER

Before any work inside the cabinet, read

the safety information in section Electrical
safety on page 32.

2
ELECTROSTATIC DISCHARGE
(ESD)

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 49.

3 Connect 24VDC power supply to X1 (power External 24VDC power supply is needed
inlet, main functions) and X20 (optional for option 1551-1.
camera power inlet) on the conveyor
tracking module.
4 Connect the Ethernet cable to the connect- The WAN port of the CTM must be con-
or X7 WAN on the conveyor tracking mod- nected to the same Ethernet network as
ule. the robot controllers.
5 Connect wires to the encoder and camera Described in the Application manual - Con-
connectors as required. veyor tracking.

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 2 Installation and commissioning
2.11.4 Installing the Safety module DSQC1015 for SafeMove

2.11.4 Installing the Safety module DSQC1015 for SafeMove

General
To use the options SafeMove Basic and SafeMove Pro you need to install the
Safety module DSQC1015 in the robot controller.
The procedure below describes how to install the Safety module and how to connect
the cables.

Location
The Safety module DSQC1015 is a PCIexpress board that is located inside the
IRC5 main computer unit.

xx1500001760

A Safety module DSQC1015

B PCIexpress slot for other devices.

Required equipment
Illustration of the cable harnesses are found in section:
• Connecting the cables to the Safety module (hardware switch and 731-1) on
page 110

Item Equipment Note

DSQC1015 Safety module 3HAC048858-001
A2 Harness safety hard Key switch 3HAC057074-001
D Harness 24 V I/O DSQC1015 3HAC057073-001
B Harness auxiliary contact 3HAC057076-001
E Harness Emergency stop 3HAC032324-001
F Harness Control (Motor on, Key switch) 3HAC049563-001

Continues on next page

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2 Installation and commissioning
2.11.4 Installing the Safety module DSQC1015 for SafeMove
Continued

Item Equipment Note

G Harness extended Key switch 3HAC057075-001
Used when the controller has the option
735-3 or 735-4 Additional contacts.
Standard toolkit The contents are defined in section Stand-
ard toolkit, IRC5 on page 209.
Circuit diagram See Circuit diagrams on page 221.

Installing the Safety module

Action Note/Illustration
1
DANGER

Before any work inside the cabinet, read

the safety information in section Electrical
safety on page 32.

2
ELECTROSTATIC DISCHARGE
(ESD)

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 49.

3 Remove the cover of the cabinet. See Removing the controller cover on
page 88.
4 Remove the computer unit. See Replacement of computer unit on
page 139.
5 Open the computer unit by removing the
attachment screws and lift off the cover.
Disconnect the fan connector.

CAUTION

Be careful with the fan cable when opening

A
and removing the upper cover. The fan
B
cable must not be stretched.

xx1300000684

A Attachment screws (4 pcs.)

B Cover
6 Remove the attachment screw on top of
the slot bracket.

Continues on next page

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 2 Installation and commissioning
2.11.4 Installing the Safety module DSQC1015 for SafeMove
Continued

Action Note/Illustration
7 Fit the Safety module in position by push-
ing it into the socket on the motherboard.

A
B

xx1500001761

A Attachment screw
B Safety module

CAUTION

Always grip the board around the edges to

avoid damage to the board or its compon-
ents.

8 Refit the attachment screw on top of the

Safety module bracket.
9 Refit the fan connector and close the com-
puter unit.

CAUTION

Be careful with the fan cable when closing

the cover. The fan cable must not be
A
squeezed.
B

xx1300000684

A Attachment screws (4 pcs.)

B Cover
10 Connect all cables according to the proced-
ures described below.

Continues on next page

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2 Installation and commissioning
2.11.4 Installing the Safety module DSQC1015 for SafeMove
Continued

Connecting the cables to the Safety module (hardware switch and 731-1)
This procedure describes how to connect the cables for a robot controller equipped
with the options Hardware switch and 731-1 Safety internal connection.

EM Stop
Safety Module
S21.3
A31.4
Motors On X6 X1

S21.2 X3 G2
D EM Stop
Key Switch
XS/XP37 X9
E S21.3
S21.1 G A2 Motors On
X6
F
A21 S21.2
K42 K43

X14
Key Switch
XS/XP38 X15

B S21.1
Safety Board
xx1600000252

Action
1
DANGER

Before any work inside the cabinet, read the safety information in section Electrical
safety on page 32.

2
WARNING

The unit is sensitive to ESD. Before handling the unit, see The unit is sensitive to
ESD on page 49.

3 Mount auxiliary contact harness contact blocks (B) on contactors K42 and K43.
4 Connect auxiliary contact harness (B) to safety hard Key switch harness (A2) at
connector XS/XP38.
5 Connect safety hard Key switch harness (A2) connector A31.4.X6 to Safety module
DSQC1015.
6 Connect connector A31.4.X1 on 24 V I/O harness (D) to safety module DSQC1015.

CAUTION

Do not connect an external power source.

7 Connect connector G2.X3 on 24 V I/O harness (D) to power distribution unit (G2).
8 Connect safety hard Key switch harness (A2) connectors X14 and X15 to the safety
board (A21).

Continues on next page

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 2 Installation and commissioning
2.11.4 Installing the Safety module DSQC1015 for SafeMove
Continued

Action
9 Connect extended Key switch harness (G) to safety hard Key switch harness (A2)
at connector XS/XP37.
10 Connect emergency stop harness (E) connector A21.X9 to the safety board.
11 Connect emergency stop harness (E) connector S21.3 to Emergency Stop on the
control panel.
12 Connect the control harness (F) connector A21.X6 to the safety board.
13 Connect the control harness (F) connector S21.2 to Motors On on the control panel.
14 Connect the control harness (F) connector S21.1 to Key Switch on the control panel.
15 Route cables properly in existing cable holders.

Continues on next page

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2 Installation and commissioning
2.11.5 Installing the Connected Services box
Continued

2.11.5 Installing the Connected Services box

Introduction
If the controller is not equipped with a Connected Services box at delivery, the box
can be installed later.
For controllers produced before August 2019, contact ABB for assistance. For
controllers produced after August 2019, use the refitting procedure in Replacement
of Connected Services box on page 180.

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 2 Installation and commissioning
2.12 Testing

2.12 Testing

Function tests
When the installation is complete, perform the function tests in section Function
tests on page 121 to verify that the safety features work properly.

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This page is intentionally left blank
 3 Maintenance
3.1 Maintenance schedule, IRC5 Compact controller

3 Maintenance
3.1 Maintenance schedule, IRC5 Compact controller

General
The IRC5 Compact robot controller must be maintained at regular intervals to
ensure its function. The maintenance activities and their respective intervals are
specified below.

Intervals

Equipment Maintenance Interval Detailed in section:

activity
Complete controller Inspection 12 months i Inspecting the IRC5 Compact con-
troller on page 116
System fans Inspection 6 months i Inspecting the IRC5 Compact con-
troller on page 116
FlexPendant Cleaning When needed Cleaning the FlexPendant on
page 119
Emergency stop Function test 12 months Function test of emergency stop on
(operating panel) page 121
Emergency stop Function test 12 months Function test of emergency stop on
(FlexPendant) page 121
Mode switch Function test 12 months Function test of mode switch on
page 122
Enable device Function test 12 months Function test of three-position en-
abling device on page 123
Motor contactors Function test 12 months Function test of motor contactors
K42, K43 K42 and K43 on page 124
Brake contactor K44 Function test 12 months Function test of brake contactor
K44 on page 125
Auto stop (tested if Function test 12 months Function test of auto stop on
used) page 126
General stop (tested Function test 12 months Function test of general stop on
if used) page 127
Reduced speed Function test During commis- Function test of reduced speed
control sioning control on page 128.
i The interval depends on the working environment of the equipment: a cleaner environment may
extend the maintenance interval and vice versa.

Function test after replacement of component

In addition to performing the function tests according to the intervals, function tests
should be performed after replacing a component in the controller.

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3 Maintenance
3.2.1 Inspection of controller

3.2 Inspection activities

3.2.1 Inspection of controller

Inspecting the IRC5 Compact controller

Use this procedure to inspect the IRC5 Compact controller.
Action Note/illustration
1
DANGER

Before any work inside the cabinet, read the safety

information in section Electrical safety on page 32.

2
WARNING

The unit is sensitive to ESD. Before handling the

unit, see The unit is sensitive to ESD on page 49.

3 Inspect connectors and cabling to make sure they

are securely fastened and cabling not damaged.
4 Inspect the system fans and ventilation holes on
the surface of the cabinet to make sure they are
clean.

A
xx1400001377

5 After cleaning: Temporarily turn the power supply

to the controller on. Inspect the fans to make sure
they function correctly. Turn the power supply back
off.

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 3 Maintenance
3.3.1 Activities

3.3 Changing/replacing activities

3.3.1 Activities

References
Certain activities to be performed as specified in the maintenance schedule are
not detailed in this chapter, but in the repair chapter. See Repair on page 129.

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3 Maintenance
3.4.1 Cleaning of the controller cabinet

3.4 Cleaning activities

3.4.1 Cleaning of the controller cabinet

Required equipment

Equipment, etc. Note

Vacuum cleaner ESD protected

Internal cleaning
Clean the cabinet interior with an ESD protected vacuum cleaner, if necessary.

Cleaning considerations
This section specifies some special considerations when cleaning the controller.
• Always use ESD protection.
• Always use cleaning equipment as specified above. Any other cleaning
equipment may shorten the life of paint work, rust inhibitors, signs, or labels.
• Always make sure 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.
• Never use compressed air or spray with a high pressure cleaner.
• Never leave the door open when cleaning the exterior.

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 3 Maintenance
3.4.2 Cleaning the FlexPendant

3.4.2 Cleaning the FlexPendant

Location
The surfaces to clean are shown in the illustration below.

xx0400000973

A Touch screen
B Hard buttons

Required equipment

Equipment, etc. Note

Soft cloth ESD protected
Water/Mild cleaning agent

Clean the touch screen

This section describes how to clean the touch screen.
Action Info/Illustration
1 Lock the screen.

en0400001221

Continues on next page

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3 Maintenance
3.4.2 Cleaning the FlexPendant
Continued

Action Info/Illustration
2 It is safe to clean the FlexPendant
when the Lock screen appears.

en0400000658

3 Clean the touch screen and hard-

ware buttons using a soft cloth and
water or a mild cleaning agent.
4 Unlock the screen, by tapping the
buttons.

en0400000658

Cleaning considerations
The section below specifies some special considerations when cleaning the
FlexPendant:
• 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.
• Do not remove any covers before cleaning the FlexPendant.
• 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.

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 3 Maintenance
3.5.1 Function test of emergency stop

3.5 Function tests

3.5.1 Function test of emergency stop

Overview
Perform this test on the emergency stop button both on the operating panel and
on the FlexPendant.

Performing the function test

Action Note
1 Make a visual inspection of the emergency If any damage is found on the emergency
stop button to make sure it is not physically stop button, it must be replaced.
damaged.
2 Start the robot system.
3 Press the emergency stop button. The test is passed if the event message
“10013 emergency stop state” appears in
the FlexPendant log.
If the event message “10013 emergency
stop state” does not appear or if the event
message “20223 Emergency stop conflict”
appears in the FlexPendant log, the test is
failed and the root cause of the failure must
be found.
4 After the test, release the emergency stop
button and press the motors on button to
reset the emergency stop state.

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3 Maintenance
3.5.2 Function test of mode switch

3.5.2 Function test of mode switch

2-position mode switch

Action Note
1 Start the robot system.
2 Start with the mode switch in manual mode This test is passed if it is possible to run
and then switch the mode switch to auto the robot in auto mode.
mode. Run the robot in auto mode. If it is not possible to run the robot in auto
mode, this test is failed and the root cause
of the failure must be found.
3 Switch the mode switch to manual mode. This test is passed if the event message
“10015 Manual mode selected” appears in
the FlexPendant log.
If the event message “10015 Manual mode
selected” is not shown in the FlexPendant
log, the test failed and the root cause of
the failure must be found.

3-position mode switch

Action Note
1 Start the robot system.
2 Start with the mode switch in manual mode This test is passed if it is possible to run
and then switch the mode switch to auto the robot in auto mode.
mode. Run the robot in auto mode. If it is not possible to run the robot in auto
mode, this test is failed and the root cause
of the failure must be found.
3 Switch the mode switch to manual full This test is passed if it is possible to run
speed mode. Run the program in manual the program in manual full speed mode.
full speed mode. If it is not possible to run the program in
manual full speed mode, this test is failed
and the root cause of the failure must be
found.
4 Switch the mode switch to manual mode. This test is passed if the event message
“10015 Manual mode selected” appears in
the FlexPendant log.
If the event message “10015 Manual mode
selected” is not shown in the FlexPendant
log, the test failed and the root cause of
the failure must be found.

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 3 Maintenance
3.5.3 Function test of three-position enabling device

3.5.3 Function test of three-position enabling device

Performing the function test

Action Note
1 Start the robot system and turn the mode
switch to manual mode.
2 Press the three-position enabling device This test is passed if the event message
to the middle position and then hold the 10011 Motors ON state appears in the
enabling device in this position. event log.
If the event message 10011 Motors ON
state does not appear, or if the event
message 20224 Enabling device conflict
appears in the event log, then the test has
failed and the root cause of the failure must
be found.
3 While still holding the three-position en- This test is passed if the event message
abling device pressed, press the enabling 10012 safety guard stop state appears in
device harder to the enable the device's the event log.
third position. If the event message 10012 Safety guard
stop state does not appear, or if the event
message 20224 Enabling device conflict
appears in the event log, then the test has
failed and the root cause of the failure must
be found.

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3 Maintenance
3.5.4 Function test of motor contactors K42 and K43

3.5.4 Function test of motor contactors K42 and K43

Performing the function test

Action Note
1 Start the robot system and turn the mode
switch to manual mode.
2 Press the three-position enabling device This test is passed if the event message
to the middle position and then hold the "10011 Motors ON state" appears in the
enabling device in this position. FlexPendant log.
If the event message "37001 Motor on ac-
tivation error" appears on the FlexPendant
log, the test is failed and the root cause of
the failure must be found.
3 Release the three-position enabling device. This test is passed if the event message
"10012 safety guard stop state" appears
in the FlexPendant log.
If the event message "20227 Motor contact-
or conflict" appears in the FlexPendant
log, the test is failed and the root cause of
the failure must be found.

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 3 Maintenance
3.5.5 Function test of brake contactor K44

3.5.5 Function test of brake contactor K44

Performing the function test

Action Note
1 Start the robot system and turn the mode
switch to manual mode.
2 Press the three-position enabling device This test is passed if the brakes is disen-
to the middle position and then hold the gaged and the manipulator can be moved.
enabling device in this position. If the Event message "50056 Joint colli-
While having eye contact with the manipu- sion" appears in the FlexPendant log, the
lator, move the joystick slightly in any dir- test is failed and the root cause of the fail-
ection to disengage the brakes. ure must be found.
3 Release the three-position enabling device This test is passed if the event message
to engage the brakes. "10012 safety guard stop state" appears
in the FlexPendant log.
If the event message "37101 Brake failure"
appears in the FlexPendant log, the test is
failed and the root cause of the failure must
be found.

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3 Maintenance
3.5.6 Function test of auto stop

3.5.6 Function test of auto stop

Performing the function test

Action Note
1 Start the robot system and change the op-
erating mode to auto mode.
2 Activate the auto stop, for example by The test is passed if the event message
opening the connected robot cell door, 20205 Auto stop open appears in the event
which has interlock connection with auto log.
stop. If the event message 20205 Auto stop
open does not appear or if the event mes-
sage 20225 Auto stop conflict appears in
the event log, then the test has failed and
the root cause of the failure must be found.

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 3 Maintenance
3.5.7 Function test of general stop

3.5.7 Function test of general stop

Performing the function test

Action Note
1 Start the robot system.
2 Activate the general stop. The test is passed if the event message
“20206 General stop open” appears in the
FlexPendant log.
If the event message “20206 General stop
open” does not appear or if the event
message “20226 General stop conflict”
appears in the Flexpendant log, the test is
failed and the root cause of the failure must
be found.

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3 Maintenance
3.5.8 Function test of reduced speed control

3.5.8 Function test of reduced speed control

Performing the function test

Action Note
1 Start the robot system and change the op-
erating mode to manual.
2 Create a test program where the robot The distance and speed must be adapted
moves along a known distance with a pro- to the current installation and robot model.
grammed speed higher than 250 mm/s.
3 Start the program in manual mode and This test is passed if the speed of the robot
measure the time it takes for the robot to does not exceed 250 mm/s, otherwise the
travel the distance. test is failed and the root cause of the fail-
ure must be found.
Tip

To get accurate results, use sensors or I/O

signals to measure the time.

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 4 Repair
4.1 Overview

4 Repair
4.1 Overview

Structure of this chapter

This chapter describes all repair activities recommended for the IRC5C Compact
and any external unit.
It is made up of separate procedures, each describing a specific repair activity.
Each procedure contains all the information required to perform the activity, for
example spare parts numbers, required special tools, and materials.
All procedures assume that the controller is easy to access from all sides and that
no additional covers or equipment are fitted.

WARNING

Repair activities not described in this chapter must only be carried out by ABB.
Otherwise damage to the mechanics and electronics may occur.

Required equipment
The details of the equipment required to perform a specific repair activity are listed
in the respective procedures.

Safety information
There are general safety information and specific safety information. The specific
safety information describes the danger and safety risks while performing specific
steps in a procedure. Make sure to read through the chapter Safety on page 17
before commencing any service work.

Note

When replacing a part on the IRC5C Compact, report to your local ABB the serial
number, the article number, and the revision of both the replaced unit and the
replacement unit.
This is particularly important for safety equipment to maintain the safety integrity
of the installation.

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4 Repair
4.2 Replacement of safety board

4.2 Replacement of safety board

Location
The safety board is located as shown in the following illustration.

xx1400001378

A Safety board

Required equipment

Equipment Note
Safety board DSQC 400 or DSQC 400E
See Controller system parts on page 211
Circuit diagram See Circuit diagrams on page 221.

Continues on next page

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 4 Repair
4.2 Replacement of safety board
Continued

Removal
Use the following procedure to remove the safety board.
Action Note/illustration
1
DANGER

Before any work inside the cabinet, read the safety

information in section Electrical safety on page 32.

2
WARNING

The unit is sensitive to ESD. Before handling the

unit, see The unit is sensitive to ESD on page 49.

3 Remove the cover of the cabinet. See Opening the IRC5 Compact
controller on page 88.
4 Disconnect all connectors. Make a note of all connections.
5 Remove the thumb screw and open the protective
cover on the front of the cabinet.
6 Disconnect three customer connectors.

xx1400002007

7 Remove the four attachment screws to remove the A B

protection cover.

xx1400001379

Continues on next page

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4 Repair
4.2 Replacement of safety board
Continued

Action Note/illustration
8 Remove the eight attachment screws.

xx1400001380

9 Gently lift the safety board out.

Refitting
Use the following procedure to refit the safety board.

Note

Always grip the board around the edges to avoid damage to the board or its
components.

Action
1
DANGER

Before any work inside the cabinet, read the safety information in section Electrical
safety on page 32.

2
WARNING

The unit is sensitive to ESD. Before handling the unit, see The unit is sensitive to ESD
on page 49.

3 Gently lift the safety board out of the ESD safe bag and fit it into position on the safety
board plate.
4 Secure the safety board with its attachment screws.
5 Refit the safety board unit protection cover.
6 Reconnect all connectors.
7 Refit the cabinet cover.
8 Perform the function tests in section Function tests on page 121 to verify that the safety
features work properly.

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 4 Repair
4.3 Replacement of I/O unit

4.3 Replacement of I/O unit

General
An I/O unit may be installed in the IRC5 Compact controller. This is specified in
DeviceNet I/O units on page 97.
How to configure the I/O unit is detailed in Operating manual - RobotStudio.

Location
The location of I/O unit is shown in the following illustration.

xx1400001381

A I/O unit

Required equipment

Equipment Note
I/O unit DSQC 652
See Controller system parts on page 211.
Circuit diagram See Circuit diagrams on page 221.

Continues on next page

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4 Repair
4.3 Replacement of I/O unit
Continued

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, read the safety

information in section Electrical safety on page 32.

2
WARNING

The unit is sensitive to ESD. Before handling the unit,

see The unit is sensitive to ESD on page 49.

3 Remove the cover of the cabinet. See Opening the IRC5 Compact
controller on page 88.
4 Disconnect the connectors from the unit. Note which connector goes
where, to facilitate reassembly.
5 Tip the unit away from the mounting rail and remove
it.

xx1400001382

Refitting
The procedure below describes how to refit the I/O unit.
Action
1
DANGER

Before any work inside the cabinet, read the safety information in section Electrical
safety on page 32.

2
WARNING

The unit is sensitive to ESD. Before handling the unit, see The unit is sensitive to ESD
on page 49.

3 Hook the unit back onto the mounting rail and snap it gently in position.
4 Reconnect all connectors disconnected during removal.
5 Refit the cabinet cover.
6 Perform the function tests in section Function tests on page 121 to verify that the safety
features work properly.

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 4 Repair
4.4 Replacement of backup energy bank

4.4 Replacement of backup energy bank

Location
The following illustration shows the location of the backup energy bank in IRC5
Compact.

A
xx1400001383

A Backup energy bank

Required equipment

Equipment Note
Backup energy bank DSQC 655
See Controller system parts on page 211.
Circuit diagram See Circuit diagrams on page 221.

Removal
The following procedure describes how to remove the backup energy bank.
Action Note/illustration
1
DANGER

Before any work inside the cabinet, read the

safety information in section Electrical safety
on page 32.

2 Remove the cover of the cabinet. See Opening the IRC5 Compact control-
ler on page 88.

Continues on next page

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4 Repair
4.4 Replacement of backup energy bank
Continued

Action Note/illustration
3 Remove the three attachment screws, and
remove the support bar.

xx1400001384

4 Remove the two attachment screws, and pull

the backup energy bank unit slightly out.

xx1400001385

5 Disconnect all connectors from the power

distribution unit.
6 Pull the backup energy bank unit out com-
pletely.

Continues on next page

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 4 Repair
4.4 Replacement of backup energy bank
Continued

Action Note/illustration
7 Remove the two attachment screws.

xx1400001386

8 Remove backup energy bank.

Refitting
The procedure below details how to refit the backup energy bank.
Action Note/illustration
1
DANGER

Before any work inside the cabinet, read the

safety information in section Electrical safety
on page 32.

2 Refit the new backup energy bank.

3 Refit the attachment screws, and tighten
them.

xx1400001386

4 Slide the backup energy bank unit half way

in.
5 Reconnect all the connectors to the power
distribution unit.

Continues on next page

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4 Repair
4.4 Replacement of backup energy bank
Continued

Action Note/illustration
6 Refit the backup energy bank unit.

xx1400001387

Note

Ensure to fit in the latches properly.

7 Refit the support bar with the three attach-

ment screws.
8 Refit the cabinet cover.
9 Perform the function tests in section Function
tests on page 121 to verify that the safety
features work properly.

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 4 Repair
4.5 Replacement of computer unit

4.5 Replacement of computer unit

Location
The computer unit is located as shown in the illustration below.

A
xx1400001363

A Computer unit

Required equipment

Equipment Note
Computer unit See Spare parts on page 211.
Standard toolkit The contents are defined in section Standard
toolkit.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the tools required.
step-by-step instructions below.
Circuit diagram See Circuit diagrams on page 221.

Continues on next page

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4 Repair
4.5 Replacement of computer unit
Continued

Removal
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 Note/illustration
1
DANGER

Before any work inside the cabinet, read the

safety information in section Electrical safety
on page 32.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before handling

the unit read the safety information in section
The unit is sensitive to ESD on page 49.

3 Open the door in the front and disconnect

all connectors from the computer unit.
4 Remove the cover of the cabinet. See Removing the controller cover on
page 88.
5 Disconnect all connectors from the computer
unit.
6 Remove the attachment screws for the axis
computer.

A
xx1500000234

A Axis computer attachment screws

Continues on next page

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 4 Repair
4.5 Replacement of computer unit
Continued

Action Note/illustration
7 Pull the axis computer slightly to release the
latches on the axis computer from the re-
cesses on the assembly plate. Push the axis
computer slightly away from the assembly
plate.

B
A
xx1500000235

A Latches
B Recesses
8 Remove the three attachment screws on the A
assembly plate.

xx1400001388

A attachment screws
9 Slide the assembly plate with computer unit
out of the controller cabinet. Lift the com-
puter unit slightly to get the wrist band button
on the bottom over the edge of the cabinet.

xx1400001447

Continues on next page

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4 Repair
4.5 Replacement of computer unit
Continued

Action Note/illustration
10 Loosen the attachment screws, and pull the
computer unit in the direction of the arrow.
The computer unit is suspended by latches
and attachment screws.

xx1400001448

WARNING

Prevent the computer unit from falling

down due to gravity by supporting the
computer unit from beneath by hand.

Refitting
The procedure below describes how to refit the computer unit.

Note

After replacing the main computer, the RobotWare system can be reset. It is then
necessary to restore a backup. For information on how to restore a backup see
Operating manual - IRC5 with FlexPendant.

Action Note/illustration
1
DANGER

Before any work inside the cabinet, read the

safety information in section Electrical safety
on page 32.

2
ELECTROSTATIC DISCHARGE
(ESD)

The unit is sensitive to ESD. Before handling

the unit read the safety information in section
The unit is sensitive to ESD on page 49.

3 Fit the computer unit in position on the as-

sembly plate.
4 Tighten the attachment screws.

Continues on next page

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 4 Repair
4.5 Replacement of computer unit
Continued

Action Note/illustration
5 Slide the assembly plate with the computer
unit into the cabinet. The computer unit
should rest on guide structure 1. Guide
structure 2 should fit between the assembly
plate and the computer unit.

A
B
xx1500000236

A Guide structure 1
B Guide structure 2
6 Make sure the computer unit spring is
clipped on to the structure wall inside the
cabinet.

B
A

xx1500000233

A Computer unit spring

B Structure wall
7 Tighten the assembly plate attachment
screws.
8 Fit the axis computer unit so that its latches
fit into the recesses of the assembly plate.
9 Tighten the axis computer unit attachment
screws.
10 Reconnect all connectors to the computer
unit.
11 Refit the cabinet cover.
12 Perform the function tests in section Function
tests on page 121 to verify that the safety
features work properly.

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4 Repair
4.6 Replacement of PCIexpress boards in the computer unit

4.6 Replacement of PCIexpress boards in the computer unit

Location
The following PCIexpress boards may be fitted in the slots in the computer unit as
shown in the figure below:
• DeviceNet Master/Slave
• PROFIBUS-DP Master
• Safety module (second generation SafeMove safety controller)

xx1500001760

A Safety module DSQC1015

B PCIexpress slot for other devices.

Required equipment

Equipment Art. no. Note

Profibus-DP Master 3HAC044872-001 DSQC1005
Profibus communication is de-
scribed in Application manu-
al - PROFIBUS Controller.
DeviceNet Master/Slave 3HAC043383-001 DSQC1006
DeviceNet communication is de-
scribed in Application manual - Devi-
ceNet Master/Slave.
Safety module 3HAC048858-001 DSQC1015
SafeMove (2nd generation) is de-
scribed in Application manual - Func-
tional safety and SafeMove2.
Standard toolkit The contents are described in sec-
tion Standard toolkit, IRC5 on
page 209.

Continues on next page

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 4 Repair
4.6 Replacement of PCIexpress boards in the computer unit
Continued

Equipment Art. no. Note

Other tools and procedures may These procedures include refer-
be required. See references to ences to tools required.
these procedures in the step-by-
step instructions below.

References

Equipment Art. no. Note

Application manual - PROFIBUS 3HAC050966-001 Contains information on how to
Controller configure the system for PROFIBUS
devices.
Application manual - DeviceNet 3HAC050992-001 Contains information on how to
Master/Slave configure the system for DeviceNet
devices.
Circuit diagram See Circuit dia-
grams on page 221.

Removal
The procedure below details how to remove a PCIexpress board.
Action Note/Illustration
1
DANGER

Before any work inside the cabinet, read

the safety information in section Electrical
safety on page 32.

2
ELECTROSTATIC DISCHARGE
(ESD)

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 49.

3 Remove the cover of the cabinet. See Removing the controller cover on
page 88.
4 Remove the computer unit. See Replacement of computer unit on
page 139.
5 Disconnect any cables to/from the PCIex-
press board. Tip

Make a note of which cables are disconnec-

ted.

Continues on next page

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4 Repair
4.6 Replacement of PCIexpress boards in the computer unit
Continued

Action Note/Illustration
6 Open the computer unit by removing the
attachment screws and lift off the upper
cover. Disconnect the fan connector.

CAUTION

Be careful with the fan cable when opening

A
and removing the upper cover. The fan
B
cable must not be stretched.

xx1300000684

A Attachment screws (4 pcs.)

B Upper cover
7 Remove the attachment screw on top of
the PCIexpress board bracket.

B
A

xx1300000685

A Attachment screw
B PCIexpress board
8 Gently pull the board straight out.
CAUTION

Always grip the board around the edges to

avoid damage to the board or its compon-
ents.

CAUTION

Immediately put the board in an ESD safe

bag or similar.

Refitting
The procedure below details how to refit a PCIexpress board.
Action Note/Illustration
1
DANGER

Before any work inside the cabinet, read

the safety information in section Electrical
safety on page 32.

Continues on next page

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 4 Repair
4.6 Replacement of PCIexpress boards in the computer unit
Continued

Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)

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 49.

3 Fit the PCIexpress board in position by

pushing the PCIexpress board into the
socket on the motherboard.

B
A

xx1300000685

A Attachment screw
B PCIexpress board

CAUTION

Always grip the board around the edges to

avoid damage to the board or its compon-
ents.

4 Refit the attachment screw on top of the

PCIexpress board bracket.
5 Reconnect any additional cables to the
PCIexpress board.
6 Refit the fan connector and close the com-
puter unit.

CAUTION

Be careful with the fan cable when closing

the upper cover. The fan cable must not be
A
squeezed.
B

xx1300000684

A Attachment screws (4 pcs.)

B Upper cover
7 Refit the computer unit. See Replacement of computer unit on
page 139.
8 Refit the controller cover.
9 Make sure the robot system is configured
to support the installed PCIexpress board.
10 Perform the function tests in section
Function tests on page 121 to verify that the
safety features work properly.

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4 Repair
4.7 Replacement of Safety module DSQC1015 for SafeMove

4.7 Replacement of Safety module DSQC1015 for SafeMove

Location
The Safety module DSQC1015 is a PCIexpress board that is located inside the
IRC5 main computer unit.

xx1500001760

A Safety module DSQC1015

B PCIexpress slot for other devices.

Required equipment

Equipment Note
DSQC1015 Safety module 3HAC048858-001
Standard toolkit The contents are defined in section Standard
toolkit, IRC5 on page 209.
Circuit diagram See Circuit diagrams on page 221.

Removing the Safety module

Action Note/Illustration
1
DANGER

Before any work inside the cabinet, read

the safety information in section Electrical
safety on page 32.

Continues on next page

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 4 Repair
4.7 Replacement of Safety module DSQC1015 for SafeMove
Continued

Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)

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 49.

3 Remove the cover of the cabinet. See Removing the controller cover on
page 88.
4 Remove the computer unit. See Replacement of computer unit on
page 139.
5 Open the computer unit by removing the
attachment screws and lift off the cover.
Disconnect the fan connector.

CAUTION

Be careful with the fan cable when opening

A
and removing the upper cover. The fan
B
cable must not be stretched.

xx1300000684

A Attachment screws (4 pcs.)

B Cover
6 Remove the attachment screw on top of
the slot bracket.
7 Remove the Safety module by pulling it out
of the socket on the motherboard.

A
B

xx1500001761

A Attachment screw
B Safety module

CAUTION

Always grip the board around the edges to

avoid damage to the board or its compon-
ents.

Continues on next page

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4 Repair
4.7 Replacement of Safety module DSQC1015 for SafeMove
Continued

Refitting the Safety module

Action Note/Illustration
1
DANGER

Before any work inside the cabinet, read

the safety information in section Electrical
safety on page 32.

2
ELECTROSTATIC DISCHARGE
(ESD)

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 49.

3 Fit the Safety module in position by push-

ing it into the socket on the motherboard.

A
B

xx1500001761

A Attachment screw
B Safety module

CAUTION

Always grip the board around the edges to

avoid damage to the board or its compon-
ents.

4 Refit the attachment screw on top of the

Safety module bracket.
5 Refit the fan connector and close the com-
puter unit.

CAUTION

Be careful with the fan cable when closing

the cover. The fan cable must not be
A
squeezed.
B

xx1300000684

A Attachment screws (4 pcs.)

B Cover
6 Refit the computer unit. See Replacement of computer unit on
page 139.
7 Refit the cover of the cabinet.

Continues on next page

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 4 Repair
4.7 Replacement of Safety module DSQC1015 for SafeMove
Continued

Action Note/Illustration
8 Perform the function tests in section
Function tests on page 121 to verify that the
basic safety features (e.g. emergency stop)
work properly.
9 Perform a synchronization. See Application manual - Functional safety
and SafeMove2.
10 Perform a Cyclic Brake Check. See Application manual - Functional safety
and SafeMove2.
11 Lock the SafeMove configuration file. See Application manual - Functional safety
and SafeMove2.

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4 Repair
4.8 Replacement of expansion board in the computer unit

4.8 Replacement of expansion board in the computer unit

Location
To connect a serial channel or a fieldbus adapter to the controller, the main
computer must be equipped with the expansion board DSQC1003.
The expansion board is located in the computer unit as shown below.

xx1300000860

A Expansion board with serial channel and one slot for AnybusCC fieldbus adapter.

Required equipment

Equipment Art. no. Note

Expansion Board 3HAC046408-001 DSQC1003

Removal
The following procedure describes how to remove the expansion board from the
computer unit.
Action Note/Illustration
1
DANGER

Before any work inside the cabinet, read

the safety information in section Electrical
safety on page 32.

Continues on next page

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 4 Repair
4.8 Replacement of expansion board in the computer unit
Continued

Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)

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 49.

3 Remove the cover of the cabinet. See Removing the controller cover on
page 88.
4 Remove the computer unit. See Replacement of computer unit on
page 139.
5 Disconnect any cables to/from the fieldbus
adapter.
6 Open the computer unit by removing the
attachment screws and lift off the upper
cover. Disconnect the fan connector.

CAUTION

Be careful with the fan cable when opening

A
and removing the upper cover. The fan
B
cable must not be stretched.

xx1300000684

A Attachment screws (4 pcs.)

B Upper cover
7 If there is a fieldbus adapter, remove it. See Replacement of fieldbus adapter in
the computer unit on page 155.
8 Remove the attachment screws on the
computer unit.

xx1300000859

A Attachment screws (2 pcs)

9 Grip the expansion board and gently pull
it straight out. CAUTION

Always grip the expansion board around

the edges to avoid damage to the board
or its components.

Continues on next page

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4 Repair
4.8 Replacement of expansion board in the computer unit
Continued

Refitting
The following procedure describes how to refit the expansion board in the computer
unit.
Action Note/Illustrator
1
DANGER

Before any work inside the cabinet, read

the safety information in section Electric-
al safety on page 32.

2
ELECTROSTATIC DISCHARGE
(ESD)

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 49.

3 Fit the expansion board in position by

pushing the expansion board into the CAUTION
connector on the motherboard.
Always grip the expansion board around the
CAUTION edges to avoid damage to the board or its
components.
Push carefully so no pins are damaged.
Make sure that the expansion board is
pushed straight into the connector.

4 Secure the expansion board in the com-

puter unit with the attachment screws.
5 Refit the fan connector and close the
computer unit.

CAUTION

Be careful with the fan cable when clos-

ing the upper cover. The fan cable must
not be squeezed.

6 Refit the computer unit. See Replacement of computer unit on

page 139.
7 Refit the controller cover.
8 Reconnect any cable to the fieldbus ad-
apter.
9 Perform the function tests in section
Function tests on page 121 to verify that
the safety features work properly.

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 4 Repair
4.9 Replacement of fieldbus adapter in the computer unit

4.9 Replacement of fieldbus adapter in the computer unit

Location
One of the following fieldbus adapters may be fitted in the slot in the computer unit
as shown in the figure below:
• AnybusCC EtherNet/IP slave
• AnybusCC PROFIBUS slave
• AnybusCC PROFINET slave
• AnybusCC DeviceNet slave

xx1300000604

A Slot for AnybusCC fieldbus adapters

Required equipment

Equipment Art. no. Note

AnybusCC EtherNet/IP slave 3HAC027652-001 DSQC 669
fieldbus adapter Ethernet/IP communication is de-
scribed in Application manual - Eth-
erNet/IP Anybus Adapter
AnybusCC PROFIBUS slave 3HAC026840-001 DSQC 667
fieldbus adapter PROFIBUS communication is de-
scribed in Application manu-
al - PROFIBUS Anybus Device
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

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4 Repair
4.9 Replacement of fieldbus adapter in the computer unit
Continued

Equipment Art. no. Note

AnybusCC DeviceNet slave 3HAC045973-001 DSQC1004
fieldbus adapter DeviceNet communication is de-
scribed in Application manu-
al - DeviceNet Anybus Slave.
Standard toolkit The contents are described in
section Standard toolkit, IRC5 on
page 209.

References

Equipment Art. no. Note

Application manual - EtherNet/IP 3HAC050997-001 Contains information on how to
Anybus Adapter configure the system for Ether-
net/IP Fieldbus Adapter DSQC 669.
Application manual - PROFIBUS 3HAC050965-001 Contains information on how to
Anybus Device configure the system for PROFIB-
US Fieldbus Adapter DSQC 667.
Application manual - PROFINET 3HAC050968-001 Contains information on how to
Anybus Device configure the system for
PROFINET Fieldbus Adapter
DSQC 688.
Application manual - DeviceNet 3HAC050993-001 Contains information on how to
Anybus Slave configure the system for DeviceNet
Fieldbus Adapter DSQC1004.
Circuit diagram See Circuit diagrams
on page 221.

Removal
The following procedure details how to remove the fieldbus adapter from the
computer unit.
Action Note/Illustration
1
DANGER

Before any work inside the cabinet, read

the safety information in section Electrical
safety on page 32.

2
ELECTROSTATIC DISCHARGE
(ESD)

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 49.

3 Remove the cover of the cabinet. See Removing the controller cover on
page 88.
4 Remove the computer unit. See Replacement of computer unit on
page 139.
5 Disconnect any cables to/from the fieldbus
adapter.

Continues on next page

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 4 Repair
4.9 Replacement of fieldbus adapter in the computer unit
Continued

Action Note/Illustration
6 Loosen the attachment screws (2 pcs) on
front of the fieldbus adapter to release the
fastening mechanism.

Note

Only loosen the attachment screws. Do not

remove them.

xx0700000193

A Attachment screws (2 pcs)

B Fastening mechanism
7 Grip the loosened attachment screws and
gently pull the fieldbus adapter straight out.

A
xx1500001755

A Fieldbus adapter

Continues on next page

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4 Repair
4.9 Replacement of fieldbus adapter in the computer unit
Continued

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, read

the safety information in section Electric-
al safety on page 32.

2
ELECTROSTATIC DISCHARGE
(ESD)

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 49.

3 Fit the fieldbus adapter in position by

pushing the fieldbus adapter along the
rails on the motherboard.

CAUTION

Push carefully so no pins are damaged.

Make sure that the adapter is pushed
straight onto the rails.

A
xx1500001755

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

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 4 Repair
4.9 Replacement of fieldbus adapter in the computer unit
Continued

Action Note/Illustrator
4 Secure the fieldbus adapter with its at-
tachment screws (2 pcs).

xx0700000193

A Attachment screws (2 pcs)

B Fastening mechanism
5 Refit the computer unit. See Replacement of computer unit on
page 139.
6 Refit the controller cover.
7 Reconnect the cable to the fieldbus ad-
apter.
8 Make sure the robot system is configured
to reflect the fieldbus adapter installed.
9 Perform the function tests in section
Function tests on page 121 to verify that
the safety features work properly.

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4 Repair
4.10 Replacement of fan in computer unit

4.10 Replacement of fan in computer unit

Location
The computer fan is located under the upper cover as shown in the figure below.

xx1300000687

Required equipment

Equipment Note
Fan See Spare parts on page 211.
Cable straps
Standard toolkit The contents are defined in section Standard
toolkit.
Other tools and procedures may be required. These procedures include references to the
See references to these procedures in the tools required.
step-by-step instructions below.
Circuit diagram See Circuit diagrams on page 221.

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, read

the safety information in section Electrical
safety on page 32.

Continues on next page

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 4 Repair
4.10 Replacement of fan in computer unit
Continued

Action Note/Illustration
2
ELECTROSTATIC DISCHARGE
(ESD)

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 49.

3 Remove the cover of the cabinet. See Removing the controller cover on
page 88.
4 Remove the computer unit. See Replacement of computer unit on
page 139.
C B A
5 Open the computer unit by removing the
upper cover attachment screws and lift off
the upper cover.

xx1300000688

A Upper cover attachment screws (4

pcs.)
B Fan attachment screw
C Upper cover
6 Disconnect the fan connector and remove
the cable straps. CAUTION

Be careful with the fan cable when opening

and removing the upper cover. The fan
cable must not be stretched.

7 Remove the fan attachment screw.

8 Remove the fan from the upper cover.

xx1300000806

Continues on next page

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4 Repair
4.10 Replacement of fan in computer unit
Continued

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, read

the safety information in section Electrical
safety on page 32.

2
ELECTROSTATIC DISCHARGE
(ESD)

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 49.

3 Refit the fan on the upper cover.

4 Refit the attachment screw.
5 Strap the fan cable to the upper cover.
CAUTION

When strapping the cable make sure that

the cable is not stretched or squeezed, and
that the cable does not get caught in the
fan.

6 Refit the computer unit. See Replacement of computer unit on

page 139.
7 Refit the controller cover.
8 Refit the fan connector and close the com-
puter unit. CAUTION

Be careful with the fan cable when closing

the upper cover. The fan cable must not be
squeezed.

9 Perform the function tests in section

Function tests on page 121 to verify that the
safety features work properly.

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 4 Repair
4.11 Replacement of SD-card memory in computer unit

4.11 Replacement of SD-card memory in computer unit

Location
The location and orientation of the SD-card memory is shown by the following
illustration.

B
A
xx1400001374

A Slot for SD-card memory

B Attachment screw

Note

Only use SD-card memory supplied by ABB.

Note

The SD-card from the computer unit DSQC1018 cannot be used in the computer
unit DSQC1024. Use the backup and restore function to move data from
DSQC1018 to DSQC1024.

CAUTION

Reformatting the SD-card or modifying the disk partition can cause irreparable
boot-up problems.

Continues on next page

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4 Repair
4.11 Replacement of SD-card memory in computer unit
Continued

Required equipment

Equipment Note
SD-card 2GB See Spare parts on page 211.

Note

Only use SD-card memory supplied by

ABB.
Includes ABB Boot Application software
to correctly reboot the robot controller.

Standard toolkit The content is described in section

Standard toolkit, IRC5 on page 209.

Removal
Use the following procedure to remove the SD-card memory.
Action
1
DANGER

Before any work inside the cabinet, read the safety information in section Electrical
safety on page 32.

2
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the unit read the safety information
in section The unit is sensitive to ESD on page 49.

3 Remove the attachment screw and open the hatch on the right hand side of the
controller.
4 Gently push the SD-card memory with your finger until it clicks, and then pull it
straight out.

Refitting
Use the following procedure to refit the SD-card memory.
Action
1
DANGER

Before any work inside the cabinet, read the safety information in section Electrical
safety on page 32.

2
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the unit read the safety information in
section The unit is sensitive to ESD on page 49.

Continues on next page

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 4 Repair
4.11 Replacement of SD-card memory in computer unit
Continued

Action
3
CAUTION

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.

4 Gently push the SD-card memory with your finger until it clicks into place.
5 Perform the function tests in section Function tests on page 121 to verify that the safety
features work properly.

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4 Repair
4.12 Replacement of drive unit

4.12 Replacement of drive unit

Location
The following illustration shows the location of the Main Drive Unit.

xx1400001449

A Main Drive Unit

Required equipment

Equipment Note
Main Drive Unit See Controller system parts on page 211.
Standard toolkit The content is described in section Standard
toolkit, IRC5 on page 209.
Other tools and procedures may be required.
See references to these procedures in the
step-by-step instructions below.

Continues on next page

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 4 Repair
4.12 Replacement of drive unit
Continued

Removal
Use the following procedure to remove the Main Drive Unit.
Action Information
1
DANGER

Before any work inside the cabinet, read the safety

information in section Electrical safety on page 32.

2 Remove the cover of the cabinet. See Opening the IRC5 Compact
controller on page 88.
3 Disconnect the connectors on the top and on the
left on the Main Drive Unit.

xx1400002850

A Connectors on the Main

Drive Unit
4 Remove the six attachment screws in the back of B
the controller.

A
xx1400001619

A Attachment screws for

Main Drive Unit
B Attachment screws for
support bar
5 Remove the support bar by removing the two attach-
ment screws.

Continues on next page

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4 Repair
4.12 Replacement of drive unit
Continued

Action Information
6 Push the Main Drive Unit out from the back of the A
controller to get free from the screws in the back B
plane. Then slide the Main Drive Module half way
out.

xx1400002851

A Screws sticking out of the

back plane of the controller
B Connectors on the Main
Drive Unit
7 Disconnect the connectors from the right side of
the Main Drive Unit.
8 Remove the Main Drive Unit from the controller.
9 Loosen the two lower attachment screws, and re- A
move the two upper screws, to remove the drive
unit from mounting frame.

B
xx1400001450

A Upper attachment (2 pcs.)

B Lower attachment (2 pcs.)

Continues on next page

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 4 Repair
4.12 Replacement of drive unit
Continued

Refitting
Use the following procedure to refit the Main Drive Unit.
Action
1
DANGER

Before any work inside the cabinet, read the safety information in section Electrical
safety on page 32.

2 Fit the unit in its intended position and orientation on the mounting frame. Secure it
with its attachment screws.
3 Slide the Main Drive Unit half way into the controller.
4 Reconnect the connectors on the right side of the Main Drive Unit.
5 Refit the Main Drive Unit in the controller and secure it with its attachment screws.
6 Refit support bar with its attachment screws.
7 Reconnect the connectors on the top and left on the Main Drive Unit.
8 Refit the cabinet cover.
9 Perform the function tests in section Function tests on page 121 to verify that the safety
features work properly.

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4 Repair
4.13 Replacement of axis computer

4.13 Replacement of axis computer

Location
The location of the axis computer is shown by the following illustration.

xx1400001451

A Axis computer unit

Required equipment

Equipment Information
Axis computer DSQC 668
See Controller system parts on page 211.
Standard toolkit The content is described in section
Standard toolkit, IRC5 on page 209.
Other tools and procedures may be required. See
references to these procedures in the step-by-
step instructions below.

Continues on next page

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 4 Repair
4.13 Replacement of axis computer
Continued

Removal
Use the following procedure to remove the axis computer.
Action Info/illustration
1
DANGER

Before any work inside the cabinet, read the

safety information in section Electrical safety
on page 32.

2
WARNING

The unit is sensitive to ESD. Before handling

the unit, see The unit is sensitive to ESD on
page 49.

3 Remove the cover of the cabinet. See Opening the IRC5 Compact controller
on page 88.
4 Disconnect all connectors from the axis
computer unit. Note

Make a note of any connections.

5 Remove the attachment screws.

A
xx1500000234

A Attachment screws
6 Slide the axis computer unit out of the con-
troller.
7 Remove the seven attachment screws and
gently lift the axis computer board straight
up.

xx1000000953

A Axis computer board

B Axis computer cover
C Attachment screws

Continues on next page

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4 Repair
4.13 Replacement of axis computer
Continued

Refitting
Use this procedure to refit the axis computer.
Action Info/illustration
1
DANGER

Before any work inside the cabinet, read the

safety information in section Electrical safety
on page 32.

2
WARNING

The unit is sensitive to ESD. Before handling

the unit, see The unit is sensitive to ESD on
page 49.

3 Gently fit the axis computer board into the

cover and refit the attachment screws.
4 Slide the axis computer unit into the control-
ler, ensuring that the latches fit into the re-
cesses.

B
A
xx1500000235

A Latches
B Recesses
5 Tighten the axis computer unit attachment
screws.
6 Reconnect all the connectors.
7 Refit the cabinet cover.
8 Perform the function tests in section Func-
tion tests on page 121 to verify that the safety
features work properly.

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 4 Repair
4.14 Replacement of contactor unit

4.14 Replacement of contactor unit

Location
The following illustration shows the location of the contactor unit in IRC5 Compact.

xx1400002008

A Contactor unit

Required equipment

Equipment Note
Contactor unit Contactor ASL16-30-10 DC24V
See Miscellaneous parts on page 214.
Circuit diagram See Circuit diagrams on page 221.

Removal
The following procedure describes how to remove the backup energy bank.
Action Note/illustration
1
DANGER

Before any work inside the cabinet, read the

safety information in section Electrical safety
on page 32.

2 Remove the cover of the cabinet. See Opening the IRC5 Compact control-
ler on page 88.

Continues on next page

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4 Repair
4.14 Replacement of contactor unit
Continued

Action Note/illustration
3 Disconnect all wires from the contactor unit. Make a note of all connections.
4 Remove the two attachment screws. A

xx1400002030

5 Remove contactor unit, and replace each

defective component.

Refitting
The procedure below details how to refit the backup energy bank.
Action
1
DANGER

Before any work inside the cabinet, read the safety information in section Electrical
safety on page 32.

2 Refit the contactor unit.

3 Refit the attachment screws, and tighten them.
4 Reconnect all wires.
5 Refit the cabinet cover.
6 Perform the function tests in section Function tests on page 121 to verify that the safety
features work properly.

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 4 Repair
4.15 Replacement of brake resistor bleeder

4.15 Replacement of brake resistor bleeder

Location
The following illustration shows the location of the brake resistor bleeder.

B C

xx1400001457

A Bleeder
B Fan cover
C Attachment screws

Required equipment

Equipment Note
Brake resistor bleeder See Miscellaneous parts on page 214.
Standard toolkit The content is described in section Standard toolkit,
IRC5 on page 209.

Removal
Use the following procedure to remove the line filter.
Action Note/illustration
1
DANGER

Before any work inside the cabin-

et, read the safety information in
section Electrical safety on
page 32.

Continues on next page

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4 Repair
4.15 Replacement of brake resistor bleeder
Continued

Action Note/illustration
2
CAUTION

Hot surface on top of the bleeder.

Risk of burns. Be careful when
removing the unit.

3 Remove the fan cover.

4 Disconnect the bleeder connect-
or. A

xx1500000119

A Bleeder connector
A
5 Loosen the two lower attachment
screws on the bleeder bracket.

xx1400001458

A Upper attachment screw

B Lower attachment screws
6 Remove the upper attachment
screw.
7 Pull the brake resistor bleeder
upwards and then outwards, to
release it from the lower screw
heads, and remove it.

Continues on next page

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 4 Repair
4.15 Replacement of brake resistor bleeder
Continued

Refitting
Use the following procedure to refit the line filter.
Action Note/illustration
1
DANGER

Before any work inside the cabin-

et, read the safety information in
section Electrical safety on
page 32.

A
2 Refit the brake resistor bleeder
by sliding the recesses in be-
neath the lower attachment
screw heads, and push it inwards
and then downwards.

xx1400001458

A Upper attachment screw

B Lower attachment screws
3 Refit the upper attachment
screw.
4 Tighten all the attachment screws
for the bleeder.
5 Reconnect the bleeder connect-
or.
6 Refit the fan cover, push it left
towards the grooves.
7 Refit the attachment screws for
the fan cover, and tighten them.
8 Perform the function tests in
section Function tests on
page 121 to verify that the safety
features work properly.

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4 Repair
4.16 Replacement of system fans

4.16 Replacement of system fans

Location
The following illustration shows the location of the system fans.

B C

xx1400001454

A System fan
B Fan cover
C Attachment screws

Required equipment

Equipment Note
Fan with receptacle See Miscellaneous parts on page 214.
Standard toolkit The content is described in section Standard
toolkit, IRC5 on page 209.

Removal
Use this procedure to remove one of the system fans.
Action Info/illustration
1
DANGER

Before any work inside the cabinet, read the

safety information in section Electrical safety
on page 32.

Continues on next page

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 4 Repair
4.16 Replacement of system fans
Continued

Action Info/illustration
2
CAUTION

Hot surface on top of the bleeder. Risk of

burns. Be careful when removing the unit.

3 Remove four attachment screws on the fan

cover.
4 Push the fan cover to the left and remove it.
5 Remove brake resistor bleeder. See Replacement of brake resistor
bleeder on page 175.
6 Disconnect the connectors to the fan.
7 Loosen the attachment screw on the fan re-
ceptacle.

xx1400001456

8 Push the fan according to illustration, to re-

lease and remove it.

Refitting
Use this procedure to refit one of the system fans.
Action Info/illustration
1
DANGER

Before any work inside the cabinet, read the

safety information in section Electrical safety
on page 32.

2 Put the fan in place and push it upwards.

3 Fasten the attachment screw on the fan re-
ceptacle.
4 Connect the connectors to the fan.
5 Refit and connect the brake resistor bleeder. See Replacement of brake resistor
bleeder on page 175.
6 Put the fan cover in place and push it to the
right.
7 Fasten the four attachment screws on the
fan cover.
8 Perform the function tests in section Func-
tion tests on page 121 to verify that the safety
features work properly.

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4 Repair
4.17 Replacement of Connected Services box

4.17 Replacement of Connected Services box

Location
The following illustration shows the location of the Connected Services box.

xx1500000230

A Attachment screws
B Safety board
C Ethernet switch
D Connected Services box

Note

The Connected Services box DSQC 680 is deprecated as of August 2019. The
new box is available in the following variants:
• 3G connection (DSQC1016)
• WiFi connection (DSQC1023)

Required equipment

Note

The spare part numbers that are listed in the table can be out of date. See the
latest spare parts of the IRC5C Compact via myABB Business Portal, [Link]-
[Link].

Continues on next page

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 4 Repair
4.17 Replacement of Connected Services box
Continued

Equipment Information
Connected Services box DSQC 680 or DSQC1016/1023
See Controller system parts on page 211.
Standard toolkit The content is described in section Standard
toolkit, IRC5 on page 209.
Other tools and procedures may be required.
See references to these procedures in the
step-by-step instructions below.
Circuit diagram See Circuit diagrams on page 221.

Removing DSQC 680

Use this procedure to remove the Connected Services box, version DSQC 680.
Action Information
1
DANGER

Before any work inside the cabinet, read the safety

information in section Electrical safety on page 32.

2
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the

unit read the safety information in section The unit
is sensitive to ESD on page 49.

3 On the cabinet front, disconnect the connectors

from the Connected Services contacts.
If you have an Ethernet switch, disconnect the
connectors from this as well.

A B
xx1400002787

A Connected Services con-

tacts
B Ethernet switch contacts
4 Remove the cover of the cabinet. See Opening the IRC5 Compact
controller on page 88.
5 Disconnect all connectors from the safety board,
Connected Services box, and Ethernet switch.
6 Remove the two attachment screws, and push the
safety board unit backwards to release the latches.

xx1400001462

Continues on next page

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4 Repair
4.17 Replacement of Connected Services box
Continued

Action Information
7 Pull the latch (A) to the left, and push the Connected
Services box out.

xx1400001460

Refitting DSQC 680

Use this procedure to refit the Connected Services box, version DSQC 680.

Note

For controllers produced before August 2019 with DSQC 680 to be replaced by
DSQC1016/1023, contact your local ABB for assistance.
For controllers produced after August 2019, use the following procedure.

Action
1
DANGER

Before any work inside the cabinet, read the safety information in section Electrical
safety on page 32.

2
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the unit read the safety information in
section The unit is sensitive to ESD on page 49.

3 Pull the latch to the left and push the Connected Services box in position on the
mounting bracket.
4 Refit the safety board unit and secure it with attachment screws.
5 Reconnect all connectors to the Connected Services box, Ethernet switch and safety
board.
6 Refit the cabinet cover.
7 Perform the function tests in section Function tests on page 121 to verify that the safety
features work properly.

Continues on next page

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 4 Repair
4.17 Replacement of Connected Services box
Continued

Removing DSQC1016/1023
Use this procedure to remove the Connected Services box, version DSQC1016/1023.
Action Information
1
DANGER

Before any work inside the cabinet, read the safety

information in section Electrical safety on page 32.

2
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the

unit read the safety information in section The unit
is sensitive to ESD on page 49.

3 Remove the top and front covers. See Opening the IRC5 Compact
controller on page 88.
4 Disconnect the antenna.
5 Remove the cable and connectors connected to:
• Safety board
• Ethernet switch (if installed)
• Connected Services Box
6 Remove the two attachment screws, and push the
safety board unit backwards to release the latches.

xx1400001462

7 Pull the latch (A) to the left, and push the Connected
Services box out.

xx1400001460

8 If installed, remove the Ethernet switch.

9 Remove the safety board from the assembly.
10 Remove the connector in the Connected Services
box.

Continues on next page

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4 Repair
4.17 Replacement of Connected Services box
Continued

Refitting DSQC1016/1023
Use this procedure to refit the Connected Services box, version DSQC1016/1023.

Note

For controllers produced before August 2019 with DSQC 680 to be replaced by
DSQC1016/1023, contact your local ABB for assistance.
For controllers produced after August 2019, use the following procedure.

Action Information
1
DANGER

Before any work inside the cabinet, read the safety

information in section Electrical safety on page 32.

2
ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the

unit read the safety information in section The unit
is sensitive to ESD on page 49.

3 For 3G variant (DSQC1016), insert the sim card in

the Connected Services box.
4 Place the Connected Services box in the bracket.

xx1800003183

5 If an Ethernet switch is used, place the Ethernet

switch on top of the Connected Services box and
secure the screws.

xx1800003184

6 Assemble the adapter cable.

xx1800003185

Continues on next page

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 4 Repair
4.17 Replacement of Connected Services box
Continued

Action Information
7 Pull the latch to the left and push the Connected
Services box in position on the mounting bracket.

xx1800003186

8 Connect the cable 3HAC068451-002 to the cable

3HAC068464-002 using the 9-pin connector. Tighten
the screws on both sides. Pin 9 is connected to PE.

xx1800003651

9 Connect the other side of PE to ground.

xx1800003377

10 Refit the safety board unit and secure it with attach-

ment screws.
11 Reconnect all connectors to the Connected Services
box, Ethernet switch, and safety board.

xx1900000462

12 Connect the antenna to the Connected Services

box.
13 If needed, remove the sheet metal in the door's up-
per left corner.

xx1800003372

14 Refit the cabinet covers.

15 Perform the function tests in section Function tests
on page 121 to verify that the safety features work
properly.

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4 Repair
4.18 Replacement of Ethernet switch

4.18 Replacement of Ethernet switch

Location
The following illustration shows the location of the Ethernet switch.

xx1500000230

A Attachment screws
B Safety board
C Ethernet switch
D Connected Services box

Required equipment

Equipment Information
Ethernet switch 3HAC034884-001
Standard toolkit The content is described in section Standard
toolkit, IRC5 on page 209.
Other tools and procedures may be required.
See references to these procedures in the
step-by-step instructions below.
Circuit diagram See Circuit diagrams on page 221.

Continues on next page

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 4 Repair
4.18 Replacement of Ethernet switch
Continued

Removal
Use this procedure to remove the Ethernet switch.
Action Information
1
DANGER

Before any work inside the cabinet, read the safety

information in section Electrical safety on page 32.

2
WARNING

The unit is sensitive to ESD. Before handling the

unit, see The unit is sensitive to ESD on page 49.

3 On the cabinet front, disconnect the connectors

from the Ethernet switch contacts.
If a Connected Services box is installed, disconnect
the connectors from this as well.

A B
xx1400002787

A Connected Services con-

tacts
B Ethernet switch contacts
4 Remove the cover of the cabinet. See Opening the IRC5 Compact
controller on page 88.
5 Disconnect all connectors from the safety board,
Ethernet switch, and Connected Services box.
6 Remove the two attachment screws, and push the
safety board unit backwards to release the latches.

xx1400001462

7 Remove the attachment screws, and lift off the

safety board.

xx1500000231

8 Remove the Ethernet switch.

Continues on next page

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4 Repair
4.18 Replacement of Ethernet switch
Continued

Refitting
Use this procedure to refit the Ethernet switch.
Action
1
DANGER

Before any work inside the cabinet, read the safety information in section Electrical
safety on page 32.

2
WARNING

The unit is sensitive to ESD. Before handling the unit, see The unit is sensitive to ESD
on page 49.

3 Refit the Ethernet switch.

4 Refit the safety board and secure it with the attachment screws.
5 Refit the safety board unit and secure it with the attachment screws.
6 Reconnect all connectors to the Ethernet switch, Connected Services box, and safety
board.
7 Refit the cabinet cover.
8 Perform the function tests in section Function tests on page 121 to verify that the safety
features work properly.

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 4 Repair
4.19.1 Replacement of power distribution unit

4.19 Replacement of power supply

4.19.1 Replacement of power distribution unit

Location
The location of the power distribution unit is shown by the following illustration.

xx1400001463

A Power distribution unit

CAUTION

Hot surface on top of the power distribution unit.

Risk of burns. Be careful when removing the unit.
Do not route or place cables on top of the power distribution unit.

Required equipment

Equipment Note
Power distribution unit DSQC 662
See Controller system parts on page 211.
Standard toolkit The content is described in section Standard toolkit,
IRC5 on page 209.

Continues on next page

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4 Repair
4.19.1 Replacement of power distribution unit
Continued

Equipment Note
Other tools and procedures may be
required. See references to these pro-
cedures in the step-by-step instructions
below.
Circuit diagram See Circuit diagrams on page 221.

Removal
Use this procedure to remove the power distribution unit.
Action Note/illustration
1
DANGER

Before any work inside the cabinet, read

the safety information in section Electric-
al safety on page 32.

2
CAUTION

Hot surface on top of the power distribu-

tion unit.
Risk of burns. Be careful when removing
the unit.

3 Remove the cover of the cabinet. See Opening the IRC5 Compact controller on
page 88.
4 Remove the three attachment screws,
and remove the support bar.

xx1400001384

Continues on next page

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 4 Repair
4.19.1 Replacement of power distribution unit
Continued

Action Note/illustration
5 Remove the two attachment screws, and
pull the backup energy bank unit slightly
out.

xx1400001385

6 Disconnect all connectors from the

power distribution unit.
7 Pull the backup energy bank unit out
completely.
8 Remove the attachment screws and lift B
the board out.

A
xx0900000549

• A: power distribution unit

• B: attachment screws

Continues on next page

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4 Repair
4.19.1 Replacement of power distribution unit
Continued

Action Note/illustration
9 Remove the two attachment screws and
cover plate.

xx1400001464

10 Remove the five attachment screws and

spring.

xx1400001465

Refitting
Use this procedure to refit the power distribution unit.
Action Note/illustration
1
DANGER

Before any work inside the cabinet, read

the safety information in section Electric-
al safety on page 32.

Continues on next page

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 4 Repair
4.19.1 Replacement of power distribution unit
Continued

Action Note/illustration
2 Put the new power distribution unit in B
place and refit the attachment screws.

A
xx0900000549

• A: power distribution unit

• B: attachment screws
3 Refit the spring and cover plate. Secure
with attachment screws.
4 Refit the power distribution unit and se-
cure with attachment screws.
5 Slide the backup energy bank unit half
way in.
6 Reconnect the connectors X1 - X9.

CAUTION

Hot surface on top of the power distribu-

tion unit.
Do not route or place cables on top of
the power distribution unit.

7 Refit the backup energy bank unit.

8 Refit the support bar with the three at-
tachment screws.
9 Refit the cabinet cover.
10 Perform the function tests in section
Function tests on page 121 to verify that
the safety features work properly.

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4 Repair
4.19.2 Replacement of system power supply

4.19.2 Replacement of system power supply

Location
The following illustration shows the location of the system power supply.

xx1400001466

A System power supply

Required equipment

Equipment Note
System power supply DSQC 661
See Controller system parts on page 211.
Standard toolkit The content is described in section Standard
toolkit, IRC5 on page 209.
Other tools and procedures may be required.
See references to these procedures in the
step-by-step instructions below.

Removal
Use the following procedure to remove the system power supply.
Action Note/Illustration
1
DANGER

Before any work inside the cabinet, read the safety

information in section Electrical safety on page 32.

Continues on next page

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 4 Repair
4.19.2 Replacement of system power supply
Continued

Action Note/Illustration
2 Remove the cover of the cabinet. See Opening the IRC5 Compact
controller on page 88.
3 Disconnect all connectors from the unit.
4 Remove the right side beam, according to illustra- A B C
tion.

xx1400001468

• A: torx counters head

screw (2 pcs)
• B: torx pan head screw (2
pcs)
• C: beam
• D: torx pan head screw
(support)
• E: support
5 Remove two attachment screws in the back of the
controller, to loosen support bracket.

xx1400001467

6 Pull the system power supply with support bracket

straight up.

Continues on next page

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4 Repair
4.19.2 Replacement of system power supply
Continued

Action Note/Illustration
7 Loosen the two lower attachment screws.
A

B
xx0900000570

• A: upper attachment
screws
• B: lower attachment screws
8 Remove the two upper attachment screws.
9 Pull the power supply unit upwards to release it
from the lower screw heads, and remove it.

Refitting
Use the following procedure to refit the system power supply.
Action Note/Illustration
1
DANGER

Before any work inside the cabinet, read the safety

information in section Electrical safety on page 32.

Continues on next page

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 4 Repair
4.19.2 Replacement of system power supply
Continued

Action Note/Illustration
2 Refit the power supply by sliding the recesses in
beneath the lower screw heads.
A

B
xx0900000570

• A: upper attachment
screws
• B: lower attachment screws
3 Refit the two upper attachment screws.
4 Tighten the attachment screws (4 pcs).
5 Refit system power supply with support bracket by A
fitting the latches into the recesses.

B C
xx1400001469

• A: support bracket
• B: recess
• C: latch
6 Refit the two attachment screws to the support
bracket in the back of the controller
7 Refit right side beam and secure with attachment
screws.
8 Reconnect all connectors to the unit.

Continues on next page

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4 Repair
4.19.2 Replacement of system power supply
Continued

Action Note/Illustration
9 Refit the cabinet cover.
10 Perform the function tests in section Function tests
on page 121 to verify that the safety features work
properly.

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 4 Repair
4.19.3 Replacement of line filter

4.19.3 Replacement of line filter

Location
The following illustration shows the location of the line filter.

xx1400001470

A Filter

Required equipment

Equipment Spare part no. Note

Line filter 3HAC037698-001 See Controller system parts on page 211.
Standard toolkit The content is de-
scribed in section
Standard toolkit, IRC5
on page 209.
Other tools and proced-
ures may be required.
See references to these
procedures in the step-
by-step instructions be-
low.

Continues on next page

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4 Repair
4.19.3 Replacement of line filter
Continued

Removal
Use the following procedure to remove the line filter.
Action Note/illustration
1
DANGER

Before any work inside the cabinet, read

the safety information in section Electric-
al safety on page 32.

2 Remove the cover of the cabinet. See Opening the IRC5 Compact controller on
page 88.
3 Disconnect connector X1 from the sys-
tem power supply.

xx1400002853

A Connector X1
B Ground connection
4 Disconnect the ground connection.
5 Disconnect and remove the safety board See Replacement of Connected Services box
unit to be able to access the secondary on page 180.
side of the line filter.
6 Disconnect the cables from L1', L2' on
the secondary side of the line filter.

xx1400002854

A Line filter connections

Continues on next page

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 4 Repair
4.19.3 Replacement of line filter
Continued

Action Note/illustration
7 Remove the two support bracket attach-
ment screws and pull the line filter out
slightly. B

xx1400002849

A Attachment screws for the support

bracket
B L1 and L2 connections
C Ground connection
8 Disconnect the cables from L1, L2 and
ground connection on the primary side
of the line filter.
9 Pull the line filter unit out.
10 Disconnect the ground cable cable from
the secondary side of the line filter.
11 Remove the four attachment screws of
the line filter and remove it from the
support bracket.

xx0900000572

A Attachment screws for the line filter

Refitting
Use the following procedure to refit the line filter.
Action Note/illustration
1
DANGER

Before any work inside the cabinet, read

the safety information in section Electric-
al safety on page 32.

Continues on next page

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4 Repair
4.19.3 Replacement of line filter
Continued

Action Note/illustration
2 Fit the line filter in position on the sup-
port bracket and secure the four attach-
ment screws.
3 Reconnect the ground cable to the sec-
ondary side of the line filter.
4 Slide the line filter into the controller.
5 Reconnect the cables to L1, L2 and
ground connection on the primary side
of the line filter.
6 Refit the line filter unit by fitting the A
latches into the recesses.

B C
xx140000XXXX

A Line filter
B Latches
C Recess
7 Secure the line filter unit with two attach-
ment screws.
8 Reconnect the cables to L1' and L2'
connections on the secondary side of
the line filter.
9 Refit the safety board unit with its two
attachment screws.
10 Reconnect all connectors to the safety
board unit.
11 Reconnect connector X1 to the system
power supply.
12 Reconnect the ground connection under
the system power supply.
13 Refit the cabinet cover.
14 Perform the function tests in section
Function tests on page 121 to verify that
the safety features work properly.

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 5 Decommissioning
5.1 Introduction

5 Decommissioning
5.1 Introduction

Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.

General
All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. These parts must also be
disposed of in accordance with the current legislation of the country in which the
robot and control unit are installed.

Disposal of storage media

Before disposal of any storage equipment (anything from an SD card to a complete
controller), make sure that all sensitive information has been deleted.

Tip

To remove all data from the SD card, use the Clean Disk function (part of
Recovery Disk function) in RobotStudio. See Operating manual - RobotStudio.

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5 Decommissioning
5.2 Environmental information

5.2 Environmental information

Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).

xx1800000058

Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
Batteries, Lithium Main computer
Copper Cables
Steel Cabinet structure, plates, screws, etc.
Plastic/rubber Cables, connectors, etc.
Aluminium Heat sinks on power supplies and drive units
Lead Electronics
Brominated flame retardants Electronics

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 6 Reference information
6.1 Introduction

6 Reference information
6.1 Introduction

General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.

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6 Reference information
6.2 Applicable standards

6.2 Applicable standards

Note

The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.

General
The product is designed in accordance with EN ISO 10218-1, Robots for industrial
environments - Safety requirements -Part 1 Robot. If there are deviations, these
are listed in the declaration of incorporation which is included on delivery.

Standards, EN ISO
The product is designed in accordance with selected parts of:
Standard Description
EN ISO 12100:2010 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
EN ISO 13849-1:2015 Safety of machinery, safety related parts of control systems -
Part 1: General principles for design
EN ISO 13850:2015 Safety of machinery - Emergency stop - Principles for design
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
ISO 9283:1998 Manipulating industrial robots, performance criteria, and related
test methods
EN ISO 14644-1:2015 i Classification of air cleanliness
EN ISO 13732-1:2008 Ergonomics of the thermal environment - Part 1
EN 61000-6-4:2007 + EMC, Generic emission
A1:2011
IEC 61000-6-4:2006 +
A1:2010
(option 129-1)
EN 61000-6-2:2005 EMC, Generic immunity
IEC 61000-6-2:2005
EN IEC 60974-1:2012 ii Arc welding equipment - Part 1: Welding power sources
EN IEC 60974-10:2014 ii Arc welding equipment - Part 10: EMC requirements
EN IEC 60204-1:2016 Safety of machinery - Electrical equipment of machines - Part
1 General requirements
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only robots with protection Clean Room.
ii Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

Continues on next page

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 6 Reference information
6.2 Applicable standards
Continued

European standards
The product is designed in accordance with selected parts of:
Standard Description
EN 614-1:2006 + A1:2009 Safety of machinery - Ergonomic design principles - Part 1:
Terminology and general principles
EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional
aspects - Principles for design

UL, ANSI, and other standards

Standard Description
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require-
ments

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6 Reference information
6.3 Unit conversion

6.3 Unit conversion

Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal

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 6 Reference information
6.4 Standard toolkit, IRC5

6.4 Standard toolkit, IRC5

General
All service (repair, maintenance and installation) instructions contain lists of tools
required to perform the specified activity. All special tools, that is, all tools that are
not considered as standard tools 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 instructions.

Contents, standard toolkit, IRC5

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

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6 Reference information
6.5 Screw joints

6.5 Screw joints

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 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
M3 0.5
M4 1.2
M5 2.5
M6 5.0

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 7 Spare parts
7.1 IRC5 Compact controller

7 Spare parts
7.1 IRC5 Compact controller

Controller system parts

A B
C

E F

G H J K
xx1400001621

Spare part no. Description Note

A 3HAC036260-001 Main Drive Unit, MDU-430C DSQC 431
B 3HAC037310-001 Safety board DSQC 400
3HAC059163-001 DSQC 400E
C 3HAC051190-001 Multipole con. XS7, XS8, XS9

Continues on next page

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7 Spare parts
7.1 IRC5 Compact controller
Continued

Spare part no. Description Note

D 3HAC037698-001 Line filter
E 3HAC043053-001 Connected Services box DSQC 680
For controllers pro-
duced earlier than
August 2019.
E 3HAC049807-001 DSQC 1016 3G DSQC 1016
Connected Services box
3HAC028459-001 Magnetic roof antenna
3HAC042958-001 Sim card
E 3HAC058038-001 DSQC 1023 WiFi DSQC 1023
Connected Services box
3HAC059424-001
E 3HAC069612-001 Retrofit kit For Connected Ser-
vices box
F 3HAC026253-001 System Power Supply DSQC 661
G See Computer unit parts on page 212.
H 3HAC029157-001 Axis computer DSQC 668
J 3HAC025562-001 Backup energy bank DSQC 655
K 3HAC026254-001 Power distribution unit DSQC 662

Computer unit parts

The illustration below shows the placement of the computer unit parts in the
recommended spare part list.

A B
xx1300000851

Continues on next page

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 7 Spare parts
7.1 IRC5 Compact controller
Continued

Spare part no. Description Type

A 3HAC042766-001 Computer unit (1 PCI slot) DSQC1000
A 3HAC050363-001 Computer unit (2 PCI slots) DSQC1018
A 3HAC058366-001 Computer unit (2 PCI slots) DSQC1024
Recommended for RobotWare 6.08
and later versions.
B 3HAC047184-003 Mass Memory with boot loader 2GB -
(previously called
DSQC1008)
C 3HAC046408-001 Expansion Board complete DSQC1003
D 3HAC031670-001 PROFINET Slave Fieldbus Adapter DSQC 688
D 3HAC026840-001 PROFIBUS Slave Fieldbus Adapter DSQC 667
D 3HAC027652-001 Ethernet/IP Slave Fieldbus Adapter DSQC 669
D 3HAC045973-001 DeviceNet Slave Fieldbus Adapter DSQC1004
E 3HAC043383-001 DeviceNet Master/Slave PCIexpress DSQC1006
E 3HAC044872-001 PROFIBUS-DP Master PCIexpress DSQC1005
F 3HAC026525-001 Fan -
- 3HAC14944-1 RS-232/422 Converter DSQC 615

I/O System parts

xx1400001381

A I/O unit

Spare part no. Description Note

A 3HAC025784-001 ADCombi I/O unit DSQC 651

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7 Spare parts
7.1 IRC5 Compact controller
Continued

Spare part no. Description Note

A 3HAC025917-001 Digital 24V I/O unit DSQC 652
* 3HAC025918-001 Digital I/O with relay outputs DSQC 653

* Mounted outside controller cabinet

Miscellaneous parts

xx1400002002

Spare part no. Description

A 3HAC051187-001 Brake resistor bleeder asm
B 3HAC037699-001 Handle for 6 mm switch
C 3HAC052287-003 Mode selector
C 3HAC052287-001 Mode selector 2 pos
D 3HAC051135-001 Fan with receptacle
3HAB2997-1 Wrist band
3HAC037700-001 Contactor ASL16-30-10 DC24V
3HAC031561-001 Auxiliary contact CA3-10
3HAC031562-001 Auxiliary contact CA3-01
3HAC052262-001 Mounting kit, 19" cabinet
3HNE 01586-1 Conveyor Tracking Unit, DSQC 377B
3HNA027579-001 CTM-01 Conveyor Tracking Module, DSQC 2000

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 7 Spare parts
7.1 IRC5 Compact controller
Continued

External operator's panel

Spare part no. Description Note

- 3HAC038671-001 External control panel box Option 733-4
- 3HAC065947-001 External Operator's panel cable 7 m Option 734-5
- 3HAC065947-004 External Operator's panel cable 15 m Option 734-1
- 3HAC065947-005 External Operator's panel cable 30 m Option 734-3

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7 Spare parts
7.2 FlexPendant parts

7.2 FlexPendant parts

FlexPendant parts

Article number Description

3HAC028357-001 FlexPendant with cable 10 m
3HAC031683-001 Cable 10 m for FlexPendant
3HAC031683-004 Cable 30 m for FlexPendant
3HAC055665-002 FlexPendant extension cable 15 m i
3HAC055665-003 FlexPendant extension cable 22 m i
3HAC055665-004 FlexPendant extension cable 30 m i
3HAC033498-001 FlexPendant holder
3HAC033596-002 FlexPendant holder upper part
i Cannot be used together with external operator's panel (option 733-3 or 733-4).

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 7 Spare parts
7.3 Manipulator cables

7.3 Manipulator cables

Signal cables, IRB 120

Spare part no. Description

3HAC068916-001 Control cable signal 3 m
3HAC068917-001 Control cable signal 7 m
3HAC068918-001 Control cable signal 15 m

Power cables, IRB 120

Spare part no. Description

3HAC032694-001 Control cable power 3 m
3HAC032695-001 Control cable power 7 m
3HAC032696-001 Control cable power 15 m

CP/CS cables IRB 120, IRB 1200, IRB 910SC

Art. no. Description Option no.

3HAC049186-001 Customer cable signal 3 m 94-6
3HAC049186-004 Customer cable signal 7 m 94-1
3HAC049186-005 Customer cable signal 15 m 94-2
3HAC049186-006 Customer cable signal 22 m 94-3
3HAC049186-007 Customer cable signal 30 m 94-4

Cable packages for IRB 140 (including signal, power and customer cables)

Art. no. Description

3HAC7996-1 Control cable power 3 m
3HAC7996-5 Control cable power 7 m
3HAC7996-6 Control cable power 15 m
3HAC7996-7 Control cable power 22 m
3HAC7996-8 Control cable power 30 m

Signal cables, IRB 260

Art. no. Description

3HAC7998-1 Control cable signal 7 m
3HAC7998-2 Control cable signal 15 m
3HAC7998-3 Control cable signal 22 m
3HAC7998-4 Control cable signal 30 m

Continues on next page

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7 Spare parts
7.3 Manipulator cables
Continued

Power cables, IRB 260

Art. no. Description

3HAC9038-1 Control cable power 7 m
3HAC9038-2 Control cable power 15 m
3HAC9038-3 Control cable power 22 m
3HAC9038-4 Control cable power 30 m

Cable packages for IRB 360 (including signal, power and customer cables)

Art. no. Description

3HAC029903-001 Control cable, power and signal 3 m
3HAC029903-002 Control cable, power and signal 7 m
3HAC029903-003 Control cable, power and signal 15 m
3HAC029903-004 Control cable, power and signal 22 m
3HAC029903-005 Control cable, power and signal 30 m
3HAC038411-001 Control cable, power and signal, stainless contact screws, 3 m
3HAC038411-002 Control cable, power and signal, stainless contact screws, 7 m
3HAC038411-003 Control cable, power and signal, stainless contact screws, 15 m
3HAC038411-004 Control cable, power and signal, stainless contact screws, 22 m
3HAC038411-005 Control cable, power and signal, stainless contact screws, 30 m

Signal cables, IRB 910SC

Spare part no. Description

3HAC057787-001 Control cable signal 3 m
3HAC057788-001 Control cable signal 7 m
3HAC057789-001 Control cable signal 15 m

Power cables, IRB 910SC

Art. no. Description

3HAC057784-001 Control cable power 3 m
3HAC057785-001 Control cable power 7 m
3HAC057786-001 Control cable power 15 m

Signal cables, IRB 1200

Spare part no. Description

3HAC068916-001 Control cable signal 3 m
3HAC068917-001 Control cable signal 7 m
3HAC068918-001 Control cable signal 15 m
3HAC068919-001 Control cable signal 22 m
3HAC068920-001 Control cable signal 30 m

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 7 Spare parts
7.3 Manipulator cables
Continued

Power cables, IRB 1200

Spare part no. Description

3HAC040503-007 Control cable power 3 m
3HAC040503-001 Control cable power 7 m
3HAC040503-002 Control cable power 15 m
3HAC040503-003 Control cable power 22 m
3HAC040503-004 Control cable power 30 m

Ethernet cables, IRB 1200

Art. no. Description Option no.

3HAC055518-001 Ethernet cable 3 m 859-9
3HAC055518-002 Ethernet cable 7 m 859-1
3HAC055518-003 Ethernet cable 15 m 859-2
3HAC055518-004 Ethernet cable 22 m 859-3
3HAC055518-005 Ethernet cable 30 m 859-4

Signal cables, IRB 1410, 1600

Art. no. Description

3HAC068917-001 Control cable signal 7 m
3HAC068918-001 Control cable signal 15 m
3HAC068919-001 Control cable signal 22 m
3HAC068920-001 Control cable signal 30 m

Power cables, IRB 1410, 1600

Art. no. Description

3HAC2492-1 Control cable power 7 m
3HAC2529-1 Control cable power 15 m
3HAC2539-1 Control cable power 22 m
3HAC2564-1 Control cable power 30 m
3HAC9038-1 Control cable power 7 m
3HAC9038-2 Control cable power 15 m
3HAC9038-3 Control cable power 22 m
3HAC9038-4 Control cable power 30 m

CP/CS cables IRB 1600

Art. no. Description Option no.

3HAC061420-001 Cable CP/CS 7 m 94-1, 16-1 and 17-5
3HAC061420-002 Cable CP/CS 15 m 94-2, 16-1 and 17-5
3HAC061420-003 Cable CP/CS 22 m 94-3, 16-1 and 17-5

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7 Spare parts
7.3 Manipulator cables
Continued

Art. no. Description Option no.

3HAC061420-004 Cable CP/CS 30 m 94-4, 16-1 and 17-5

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 8 Circuit diagrams
8.1 Circuit diagrams

8 Circuit diagrams
8.1 Circuit diagrams

Overview
The circuit diagrams are not included in this manual, but are available for registered
users on myABB Business Portal, [Link].
See the article numbers in the tables below.

Controllers

Product Article numbers for circuit diagrams

Circuit diagram - IRC5 3HAC024480-011
Circuit diagram - IRC5 Compact 3HAC049406-003
Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020
troller
Circuit diagram - Euromap 3HAC024120-004
Circuit diagram - Spot welding cabinet 3HAC057185-001

Robots

Product Article numbers for circuit diagrams

Circuit diagram - IRB 120 3HAC031408-003
Circuit diagram - IRB 140 type C 3HAC6816-3
Circuit diagram - IRB 260 3HAC025611-001
Circuit diagram - IRB 360 3HAC028647-009
Circuit diagram - IRB 460 3HAC036446-005
Circuit diagram - IRB 660 3HAC025691-001
Circuit diagram - IRB 760 3HAC025691-001
Circuit diagram - IRB 1200 3HAC046307-003
Circuit diagram - IRB 1410 3HAC2800-3
Circuit diagram - IRB 1600/1660 3HAC021351-003
Circuit diagram - IRB 1520 3HAC039498-007
Circuit diagram - IRB 2400 3HAC6670-3
Circuit diagram - IRB 2600 3HAC029570-007
Circuit diagram - IRB 4400/4450S 3HAC9821-1
Circuit diagram - IRB 4600 3HAC029038-003
Circuit diagram - IRB 6400RF 3HAC8935-1
Circuit diagram - IRB 6600 type A 3HAC13347-1
3HAC025744-001
Circuit diagram - IRB 6600 type B 3HAC13347-1
3HAC025744-001

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8 Circuit diagrams
8.1 Circuit diagrams
Continued

Product Article numbers for circuit diagrams

Circuit diagram - IRB 6620 3HAC025090-001
Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001
Circuit diagram - IRB 6640 3HAC025744-001
Circuit diagram - IRB 6650S 3HAC13347-1
3HAC025744-001
Circuit diagram - IRB 6660 3HAC025744-001
3HAC029940-001
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

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 Index

Index function tests, 121

G
A general stop, 127
allergenic material, 32
aluminum H
disposal, 204 hanging
assessment of hazards and risks, 32 installed hanging, 32
automatic mode, 31 hazard levels, 22
auto stop hazardous material, 204
function test, 126 height
installed at a height, 32
B hold-to-run, 29
batteries HRA, 32
disposal, 204
brake contactor, 125 I
brominated flame retardants I/O contact XS7, 76
disposal, 204 installation space, 43
integrator responsibility, 32
C IP class, 41
cabinet lock, 33 ISO 13849-1, 18
cables, 217
carbon dioxide extinguisher, 33 K
category 0 stop, 26 key of the mode switch, 34
category 1 stop, 26
category 3, 18 L
CCF, 18 labels
cleaning of the controller, 118 controller, 23
cleaning the FlexPendant, 119 lead
climbing on robot, 35 disposal, 204
Common Cause Failures, 18 limitation of liability, 17
Connected Services, 180 Lithium
connecting a USB memory, 91 disposal, 204
connection lock and tag, 33
FlexPendant, 54
controller M
symbols, 23 maintenance schedule, 115
copper manipulator cables, 217
disposal, 204 manual mode, 30
memory, 163
D memory functions, 90
DC, 18 mode switch, 122
DeviceNet contact XS11, 77–78 mode switch key, 34
Diagnostic Coverage, 18 motor contactors, 124
disposal of storage media, 203 MTTFD, 18–19
DSQC1015, 148
N
E national regulations, 32
emergency stop, 26, 121 network security, 15
definition, 26
emergency stops, 28 O
enabling device, 29, 103 operating conditions, 41
function test, 123 operating mode
EN ISO 13849-1, 18, 20 automatic mode, 31
environmental information, 204 manual mode, 30
ESD original spare parts, 17
damage elimination, 49
sensitive equipment, 49 P
Ethernet switch, 186 PCIexpress boards, replace, 144
expansion board, replace, 152 pedestal
external enabling device, 103 installed on pedestal, 32
external operator’s panel, 100 performance level, PL, 18
personnel
F requirements, 21
fieldbus adapter, replace, 155 PFHD, 20
fire extinguishing, 33 PL, performance level, 18
FlexPendant plastic
connecting, 54 disposal, 204

Product manual - IRC5 Compact 223

3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
Index

power cables, 217 safety module, 107, 144

power supply contact XS10, 76 Safety module, 148
PPE, 21 safety signals
product standards, 206 in manual, 22
protection class, 41 safety standards, 206
protective equipment, 21 SD-card memory, replace, 163
protective stop signal cables, 217
definition, 26 signals
protective wear, 21 safety, 22
standards, 206
R ANSI, 207
reduced speed control CAN, 207
function test, 128 EN, 207
regional regulations, 32 EN IEC, 206
Remote Service, 180 EN ISO, 206
removing steel
top cover, 88 disposal, 204
replacements, report, 129 stop category 0, 26
replacing stop category 1, 26
Connected Services box, 180 stops
Ethernet switch, 186 overview, 26
expansion board, 152 storage conditions, 41
fieldbus adapter, 155 symbols
PCIexpress boards, 144 safety, 22
Remote Service box, 180 system integrator requirements, 32
SD-card memory, 163
report replacements, 129 T
required performance level, PLr, 18 temperature, 41
responsibility and validity, 17 three-position enabling device, 29
robot cables, 217 function test, 123
rubber tightening torque, 210
disposal, 204 top cover, 88
troubleshooting
S safety, 36
safeguarding, 26
safeguard mechanisms U
automatic mode, 31 USB ports, 91
manual mode, 30 users
SafeMove, 107, 144, 148 requirements, 21
safety
emergency stop, 26 V
ESD, 49 validity and responsibility, 17
fire extinguishing, 33
signals, 22 W
signals in manual, 22 weight, 41
stop functions, 26
symbols, 22 X
symbols on controller, 23 XS7 I/O, 76
safety contact XS9, 75 XS9 Safety, 75
safety devices, 33 XS10 Power Supply, 76
XS11 DeviceNet, 77–78

224 Product manual - IRC5 Compact

3HAC047138-001 Revision: M
© Copyright 2009-2020 ABB. All rights reserved.
ABB AB, Robotics
Robotics and Motion
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400

ABB AS, Robotics

Robotics and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics and Motion
No. 4528 Kangxin Highway
PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666

ABB Inc.
Robotics and Motion
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000

[Link]/robotics
3HAC047138-001, Rev M, en

© Copyright 2009-2020 ABB. All rights reserved.

Specifications subject to change without notice.