ABB IRC5 Compact Product Manual

Workspace R18-2 version a11 Checked in 2018-10-11 Skribenta version 5.3.008

Revision: M © Copyright 2004-2018 ABB. All rights reserved. Specifications subject to change without notice.

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, damages to persons or property, fitness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this 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 2004-2018 ABB. All rights reserved. Specifications subject to change without notice. ABB AB, Robotics Robotics and Motion Se-721 68 Västerås Sweden

9 Overview of this manual ................................................................................................................... 13 Product documentation .................................................................................................................... 15 Network security ............................................................................................................................... 17 1 Safety 17 1.1 General safety information .................................................................................. 17 1.1.1 Limitation of liability ................................................................................. 19 1.1.2 Safety data ............................................................................................. 23 1.1.3 Protective stop and emergency stop ........................................................... 25 1.2 Safety actions ................................................................................................... 25 1.2.1 Fire extinguishing .................................................................................... 26 1.2.2 Make sure that the main power has been switched off .................................... 27 1.2.3 Enabling device and hold-to-run functionality ............................................... 28 1.2.4 Recover from emergency stops ................................................................. 29 1.2.5 Safety during troubleshooting .................................................................... 30 1.3 Safety risks ...................................................................................................... 30 1.3.1 Safety risks during installation and service work on robots .............................. 32 1.3.2 Risks associated with live electric parts ....................................................... 34 1.3.3 The unit is sensitive to ESD ....................................................................... 35 1.3.4 Close the cabinet door ............................................................................. 36 1.3.5 Hot components in controller ..................................................................... 37 1.3.6 Make sure that all mode selector keys are kept safe ...................................... 38 1.3.7 Risk of disabling function "Reduced speed 250 mm/s" ................................... 39 1.4 Safety signals and symbols ................................................................................. 39 1.4.1 Safety signals in the manual ...................................................................... 41 1.4.2 Safety symbols on controller labels ............................................................ 45 2 Installation and commissioning 45 2.1 Overview ......................................................................................................... 47 2.2 Installation activities .......................................................................................... 48 2.3 Transporting and handling .................................................................................. 48 2.3.1 Lifting the controller cabinet ...................................................................... 49 2.3.2 Unpacking the controller ........................................................................... 51 2.4 On-site installation ............................................................................................ 51 2.4.1 Required installation space, IRC5 Controller ................................................ 52 2.4.2 Bolting down the controller ....................................................................... 53 2.4.3 Transportation screws .............................................................................. 54 2.4.4 Mounting the FlexPendant holder ............................................................... 58 2.5 Connections ..................................................................................................... 58 2.5.1 Connectors on the controller ..................................................................... 59 2.5.2 Connecting cables to the controller ............................................................. 65 2.5.3 Power supply system requirements ............................................................ 68 2.5.4 Connecting power supply to the controller ................................................... 73 2.5.5 Connecting the manipulator to the controller ................................................ 74 2.5.6 Connecting safety signals ......................................................................... 76 2.5.7 Connecting a FlexPendant ........................................................................ 77 2.5.8 Using the hot plug option .......................................................................... 80 2.5.9 Connectors on the computer unit ............................................................... 83 2.5.10 Connecting a serial channel to the controller ................................................ 85 2.5.11 Programmable stop functions .................................................................... 88 2.5.12 The MOTORS ON/MOTORS OFF circuit ..................................................... 94 2.5.13 Connection of external safety relay ............................................................. 95 2.5.14 Connection to MOTORS ON/MOTORS OFF contactor .................................... 97 2.5.15 Connection of drive module ...................................................................... 98 2.5.16 Connection of Drive Module Disconnect, by limit switch ................................. 102 2.5.17 Connection of servo disconnect, by servo power switch ................................. Product manual - IRC5 5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. Table of contents

107 2.6 Drive system .................................................................................................... 107 2.6.1 Drive functions, general ............................................................................ 108 2.6.2 Configuration of the drive system ............................................................... 111 2.7 Memory functions .............................................................................................. 111 2.7.1 Memory functions .................................................................................... 112 2.7.2 Connecting a USB memory ....................................................................... 114 2.8 I/O system ....................................................................................................... 114 2.8.1 Definition of fieldbuses, IRC5 .................................................................... 118 2.8.2 Local I/O devices ..................................................................................... 119 2.8.3 DeviceNet I/O units .................................................................................. 121 2.9 Installation of add-ons ........................................................................................ 121 2.9.1 Installation of external operator's panel, IRC5 ............................................... 125 2.9.2 Installation of external enabling device ........................................................ 127 2.9.3 Installation of Local I/O devices ................................................................. 130 2.9.4 Installation of DeviceNet I/O, Gateways and encoder interface units, IRC5 ......... 132 2.9.5 Installation of cooling fan harness axis 1 and 2 ............................................. 135 2.9.6 Installation of the option Hot plug ............................................................... 139 2.9.7 Installing the EPS board DSQC 646 for Electronic Position Switches ................ 145 2.9.8 Installing the SafeMove board DSQC 647 .................................................... 153 2.9.9 Installing the Safety module DSQC1015 for SafeMove .................................... 164 2.9.10 Installation of DispensePac support ............................................................ 165 2.9.11 Installation of additional drive units ............................................................. 172 2.9.12 Installation of additional Drive Module ......................................................... 173 2.9.13 Process module ...................................................................................... 176 2.9.14 Installation of drive system fans with temperature sensors .............................. 182 2.10 Testing ............................................................................................................ 183 3 Maintenance 183 3.1 Maintenance schedule, controller IRC5 ................................................................. 185 3.2 Inspection activities ........................................................................................... 185 3.2.1 Inspection of the controller ........................................................................ 187 3.3 Changing/replacing activities ............................................................................... 187 3.3.1 Replacement of moist dust filter ................................................................. 190 3.4 Cleaning activities ............................................................................................. 190 3.4.1 Cleaning of the controller cabinet ............................................................... 191 3.4.2 Cleaning moist dust filter .......................................................................... 193 3.4.3 Cleaning the FlexPendant ......................................................................... 196 3.5 Function tests ................................................................................................... 196 3.5.1 Function test of earth fault breaker F4 ......................................................... 197 3.5.2 Function test of emergency stop ................................................................ 198 3.5.3 Function test of mode switch ..................................................................... 199 3.5.4 Function test of three-position enabling device ............................................. 200 3.5.5 Function test of motor contactors K42 and K43 ............................................ 201 3.5.6 Function test of brake contactor K44 .......................................................... 202 3.5.7 Function test of auto stop ........................................................................ 203 3.5.8 Function test of general stop .................................................................... 204 3.5.9 Function test of superior stop ................................................................... 205 3.5.10 Function test of limit switch ....................................................................... 206 3.5.11 Function test of automatic fuse F1 .............................................................. 207 3.5.12 Function test of reduced speed control ........................................................ 209 4 Repair 209 4.1 Overview ......................................................................................................... 210 4.2 Replacement of panel board ................................................................................ 213 4.3 Replacement of Flange disconnect ....................................................................... 216 4.4 Replacement of I/O units and Gateways ................................................................ 218 4.5 Replacement of backup energy bank .................................................................... 220 4.6 Replacement of heat exchange unit and fan ........................................................... 6 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. Table of contents

228 4.8 Replacement of PCIexpress boards in the computer unit .......................................... 232 4.9 Replacement of expansion board in the computer unit ............................................. 235 4.10 Replacement of fieldbus adapter in the computer unit .............................................. 240 4.11 Replacement of fan in computer unit ..................................................................... 243 4.12 Replacement of SD-card memory in computer unit .................................................. 246 4.13 Replacement of drive units .................................................................................. 249 4.14 Replacement of Axis computer ............................................................................ 251 4.15 Replacement of EPS board DSQC 646 for Electronic Position Switches ...................... 255 4.16 Replacement of SafeMove board DSQC 647 ........................................................... 259 4.17 Replacement of Safety module DSQC1015 for SafeMove .......................................... 262 4.18 Replacement of Remote Service box .................................................................... 265 4.19 Replacement of Contactor Interface Board ............................................................. 268 4.20 Replacement of drive system fans ........................................................................ 271 4.21 Replacement of sensors for the drive system fans ................................................... 275 4.22 Replacement of transformer unit .......................................................................... 278 4.23 Replacement of brake resistor bleeder .................................................................. 283 4.24 Replacement of Process Interface Board ............................................................... 285 4.25 Replacement of Ethernet switch ........................................................................... 287 4.26 Replacement of power supply .............................................................................. 287 4.26.1 Replacement of power distribution unit ........................................................ 290 4.26.2 Replacement of customer I/O power supply ................................................. 293 4.26.3 Replacement of system power supply ......................................................... 297 5 Decommissioning 297 5.1 Introduction ...................................................................................................... 298 5.2 Environmental information .................................................................................. 299 6 Reference information 299 6.1 Introduction ...................................................................................................... 300 6.2 Applicable standards ......................................................................................... 302 6.3 Unit conversion ................................................................................................. 303 6.4 Screw joints ..................................................................................................... 304 6.5 Weight specifications ......................................................................................... 305 6.6 Standard toolkit, IRC5 ........................................................................................ 306 6.7 Lifting accessories and lifting instructions .............................................................. 307 7 Spare parts 307 7.1 Controller parts ................................................................................................. 313 7.2 FlexPendant parts ............................................................................................. 314 7.3 Manipulator cables ............................................................................................ 314 7.3.1 Manipulator cables .................................................................................. 318 7.3.2 Fan cables ............................................................................................. 319 7.3.3 CP/CS Harness ....................................................................................... 320 7.3.4 Cables customer power/customer signal ..................................................... 322 7.3.5 Other customer cables ............................................................................. 323 7.3.6 Additional cables ..................................................................................... 325 8 Circuit diagrams 325 8.1 Circuit diagrams ................................................................................................ 327 Index Product manual - IRC5 7 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. Table of contents

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 Document ID Reference 3HAC027098-001 Operating manual - Emergency safety information 3HAC050941-001 Operating manual - IRC5 with FlexPendant 3HAC032104-001 Operating manual - RobotStudio 3HAC027097-001 Operating manual - Getting started, IRC5 and RobotStudio 3HAC020738-001 Operating manual - Troubleshooting IRC5 3HAC050961-001 Application manual - MultiMove 3HAC050377-001 Application manual - Force Control 3HAC050974-001 Application manual - SafeMove1 3HAC050996-001 Application manual - Electronic Position Switches 3HAC052610-001 Application manual - Functional safety and SafeMove2 3HAC050917-001 Technical reference manual - RAPID Instructions, Functions and Data types 3HAC050948-001 Technical reference manual - System parameters 3HAC047400-001 Product specification - Controller IRC5 See Circuit diagrams on page 325. Continues on next page Product manual - IRC5 9 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. Overview of this manual

RobotWare 6. Equivalent documents are available for RobotWare 5. Revisions Description Revision First edition. - Released with the new computer unit, DSQC1000. • Added information on how to replace the fan in the computer unit, see Replacement of fan in computer unit on page 240. • Corrected the spare parts list for controller system parts, see Controller parts on page 307. • Added information on how to install an additional drive module, see Installation of additional Drive Module on page 172. • Added information on how to install an additional drive unit, see Install- ation of additional drive units on page 165. • Added the IRB 1520 manipulator cables to the spare parts list, see Manipulator cables on page 314. A • Added the MultiMove switch to the spare parts list, see Controller parts on page 307. • Article numbers for manipulator cables, IRB 120 added, see Manipu- lator cables on page 314. • Article number for DeviceNet Slave (DSQC 1004) changed. See Definition of fieldbuses, IRC5 on page 114 • Added information about labels on the controller, see Safety symbols on controller labels on page 41. • Minor corrections. B • New computer unit, DSQC1018, with two PCI slots and no knockout plates. No functional change, but affects illustrations. • Added new section, Additional cables on page 323, with drive module cables. • Added section Process module on page 173. • Clarified the use of the WAN port in section Connectors on the com- puter unit on page 80. C • Some changes on how the ports can be configured and used is de- scribed in section Connectors on the computer unit on page 80. D Release 15.2. • Minor corrections. • Added safety-related information to sections Make sure that all mode selector keys are kept safe on page37, Installation of external enabling device on page 125, Function tests on page 196, and Refurbish. • Updates in section Applicable standards on page 300. • Added section Safety data on page 19. • Added section Replacement of sensors for the drive system fans on page271. Also some information about the temperature sensors when replacing MDU and drive system fans. • Updated picture and table of cables to the hot plug connector in section Installation of the option Hot plug on page 135. • System fan removed E Continues on next page 10 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. Overview of this manual Continued

manual. • Changed recommended line fusing for some robots at low voltage. • Added section Installation of drive system fans with temperature sensors on page 176. • Simplified procedure in section Replacement of fieldbus adapter in the computer unit on page 235. F Release 16.1/RW 6.03. • Caution about routing cables added in General on page 59. • Section Connection of drive module on page 97 added. • Added section Installing the Safety module DSQC1015 for SafeMove on page 153. G Release 16.2. • Added information that function tests should be performed after repla- cing a component. • Changes in the article names for some spare parts. • Updated cable list with revised option numbers in section Cables customer power/customer signal on page 320. • Removed section Refurbish. • Minor corrections. H Release 17.1. • Added sections Function test of reduced speed control on page 207, and Recover from emergency stops on page 28. • Updated descriptions of stops in section Protective stop and emergency stop on page 23. • Updated section Safety data on page 19. • Updated list of labels in section Safety symbols on controller labels on page 41. • New computer unit DSQC1024 is introduced, see Computer unit parts on page 311. • Added limitation about SafeMove in section Connection of Drive Module Disconnect, by limit switch on page 98. • Minor corrections. J Release 17.2. • Updated list of applicable standards. • Updated section Connecting cables to the controller on page 59. • Added section Power supply system requirements on page 65. • Added sections Local I/O devices on page118, Installation of Local I/O devices on page 127 and Local I/O devices on page 310. • Clarified the existing information in sections DeviceNet I/O units on page 119 and Installation of DeviceNet I/O, Gateways and encoder in- terface units, IRC5 on page 130. • Updated spare parts for bleeders, see Miscellaneous parts on page312. • Removed all references to computer unit DSQC1024. • Minor corrections. • Updated section Installation of additional Drive Module on page 172. K Continues on next page Product manual - IRC5 11 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. Overview of this manual Continued

the Safety module DSQC1015 for SafeMove on page 153. • Updated to correct and consistent naming convention: DSQC1015 is called Safety module. • Added section FlexPendant parts on page 313. • Safety section restructured. • Added section about transformers to Connecting power supply to the controller on page 68. • 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 82. L Release 18.2. • Added note in section Connection of ES1/ES2 on panel unit on page91, about emergency stop signals for controller with safety module. • Added information about cables for IRB 120 in section Cables customer power/customer signal on page 320. • New computer unit DSQC1024 added, see Computer unit parts on page 311. • Added note in section Replacement of SD-card memory in computer unit on page 243, that SD-card from DSQC1018 cannot be used in DSQC1024. M 12 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. Overview of this manual Continued

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, www.myportal.abb.com. 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. Continues on next page Product manual - IRC5 13 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. Product documentation

are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. 14 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. Product documentation Continued

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 damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information. Product manual - IRC5 15 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. Network security

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 complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system. In particular, liability cannot be accepted if injury/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 made in or around the robot. • Repairs carried out by in-experienced or non-qualified personnel. • Foreign objects. • Force majeure. Nation/region specific regulations To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed. To be observed by the supplier of the complete system The integrator is responsible 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 and machines: • The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function. • The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function. Continues on next page Product manual - IRC5 17 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.1.1 Limitation of liability

hazards and risks (HRA). Note The integrator is responsible for the safety of the final application. Safe access The robot system shall be designed to allow safe access to all areas where intervention is necessary during operation, adjustment, and maintenance. Where it is necessary to perform tasks within the safeguarded space there shall be safe and adequate access to the task locations. Safety zones, which must be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices. Turntables or the like should be used to keep the operator out of the robot's working space. A safety fence is recommended to ensure safeguarded space. Sufficient space must be provided around the manipulator to protect those working with or on it from hazards such as crushing. The fence or enclosure must be dimensioned to withstand the force created if the load being handled by the robot is dropped or released at maximum speed. Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell (see the section Robot motion in the Product specification). Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot. Safe handling Users shall not be exposed to hazards, including slipping, tripping, and falling hazards. It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves). Safe design Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly. If any of the buttons do not stop all the robot workcell motion, each emergency stop button must be marked, if more than one is provided, to indicate its designated safety function. Grippers/end effectors must be designed so that they do not drop work pieces/tools in the event of a power failure or a disturbance to the controller. Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB, it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength of the robot could be affected. 18 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.1.1 Limitation of liability Continued

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 In addition to these standards covering general machinery safety, a number of more specialized standards referred to as normative, must also be fulfilled. See EN ISO 10218-1 chapter Normative references. 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. Continues on next page Product manual - IRC5 19 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.1.2 Safety data

• Enabling device • Emergency stop on operator panel • Emergency stop on FlexPendant • Limiting robot motion • Protective stops • SafeMove • EPS • 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. IRC5 Single and IRC5 Panel Mounted Controller DCavg Calculated MTTFD [years] Safety function Medium 112 Emergency stop inputs Medium 120 Automatic stop input Medium 120 General stop input Medium 120 Superior stop input Medium 176 Limiting switch input (without customer connection) Medium 75 Three-position enabling device inputs Medium 263 Emergency stop status outputs Medium 58 lSafeMove (option) (without customer connections) Medium 105 Electronic Position Switches (option) (without customer connections) SafeMove2 functions (option) Medium 93 Protective stop category 0 Low 370 Protective stop category 1 Medium 93 Emergency stop category 0 Low 370 Emergency stop category 1 Low 370 Emergency stop safe fieldbus output Medium 93 Speed supervision category 0 Low 370 Speed supervision category 1 Low 370 Speed supervision safe fieldbus output Medium 93 Position supervision category 0 Continues on next page 20 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.1.2 Safety data Continued

Low 370 Position supervision safe fieldbus output Low 88 External power control 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. IRC5 Single and IRC5 Panel Mounted Controller PL Calculated PFHD Stop circuit e 4.29x10E-08 Emergency stop inputs e 4.29x10E-08 Automatic stop input e 4.29x10E-08 General stop input e 4.29x10E-08 Superior stop input e 4.29x10E-08 Limiting switch input (without customer connection) e 6.62x10E-08 Three-position enabling device inputs e 4.29x10E-08 Emergency stop status outputs d 1.03x10E-07 SafeMove (option) (without customer connections) e 4.29x10E-08 Electronic Position Switches (option) SafeMove2 functions (option) e 4.94x10E-08 Protective stop category 0 d 1.01x10E-07 Protective stop category 1 e 4.94x10E-08 Emergency stop category 0 d 1.01x10E-07 Emergency stop category 1 d 1.01x10E-07 Emergency stop safe fieldbus output e 4.94x10E-08 Speed supervision category 0 d 1.01x10E-07 Speed supervision category 1 d 1.01x10E-07 Speed supervision safe fieldbus output e 4.94x10E-08 Position supervision category 0 d 1.01x10E-07 Position supervision category 1 d 1.01x10E-07 Position supervision safe fieldbus output d 1.35x10E-07 External power control 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. Continues on next page Product manual - IRC5 21 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.1.2 Safety data Continued

22 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.1.2 Safety data Continued

Overview Protective stops and emergency stops are defined by standards IEC 60204-1:2005 and EN ISO 10218-1:2011. Stops can be in category 0 or category 1. As defined in IEC 60204, stopping by immediate removal of power to the machine actuators (i.e. an uncontrolled stop. In IRC5 this is implemented by removing power immediately in the drive units. Stop category 0 As defined in IEC 60204, a controlled stop with power available to the machine actuators to achieve the stop and then removal of power when the stop is achieved. In IRC5 this is implemented by removing power in the drive units after about 1 second using the servos to stop the machine. Stop category 1 Inputs to initiate a protective stop or an emergency stop There are several safety inputs available to initiate a protective stop or an emergency stop. All these safety inputs are of structure category 3 as described in EN ISO 13849-1. These safety inputs will initiate a stop of category 0 or category 1. Description Safety inputs to initiate a stop The safety input Automatic Stop is only operational in automatic mode. Protective stop in automat- ic mode The default configuration is stop category 1. There are two safety inputs to initiate a protective stop in both automatic and manual mode. It is the safety input General Stop and the safety input Superior Stop. Protective stop in automat- ic and manual mode The default configuration is stop category 1. The Emergency Stop is operational in both automatic and manual mode. Emergency stop The default configuration is stop category 0. To modify the configuration of the stop category, see Technical reference manual - System parameters. Protective stop Protective stops are activated through the dedicated safety inputs Automatic Stop, General Stop, and Superior Stop, on the controller. For example, the protective inputs are connected to safety outputs of presence sensing devices. This is to provide safeguarding. See Installation and commissioning in the product manual for the robot controller. Continues on next page Product manual - IRC5 23 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.1.3 Protective stop and emergency stop

measures and other safety functions but should be designed for use as a complementary protective measure. (See ISO 13850.) Note Emergency stop must not be used for protective stop or program stop as this causes extra, unnecessary wear on the robot. For how to perform program stops, see Operating manual - IRC5 with FlexPendant. Depending on selected options for the robot, the number of emergency stops can vary. See documentation for the robot and the complete machine. Other methods to stop the robot There are also other methods to stop the robot. See: • Installation and commissioning in the product manual for the robot controller • Technical reference manual - System parameters • Technical reference manual - RAPID Instructions, Functions and Data types 24 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.1.3 Protective stop and emergency stop Continued

1.2.1 Fire extinguishing Note Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the manipulator or controller. Product manual - IRC5 25 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.2.1 Fire extinguishing

Description Working with high voltage is potentially lethal. Persons subjected to high voltage may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these personal injuries, switch off the main power on the controller before proceeding work. Note Switch off all main power switches in a MultiMove system. Main power switch Note Action xx0600003255 Switch off the main switch for the controller. 1 Disconnect the input power cable from the wall socket. 26 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.2.2 Make sure that the main power has been switched off

Three-position enabling device The three-position enabling device is a manually operated, constant pressure push-button which, when continuously activated in one position only, allows potentially hazardous functions but does not initiate them. In any other position, hazardous functions are stopped safely. The three-position enabling device is of a specific type where you must press the push-button only half-way to activate it. In the fully in and fully out positions, operating the robot is impossible. Note The three-position enabling device is a push-button located on the teach pendant which, when pressed halfway in, switches the system to MOTORS ON. When the enabling device is released or pushed all the way in, the manipulator switches to the MOTORS OFF state. To ensure safe use of the teach pendant, the following must be implemented: • The enabling device must never be rendered inoperational in any way. • During programming and testing, the enabling device must be released as soon as there is no need for the robot to move. • Anyone entering the working space of the robot must always hold the teach pendant. This is to prevent anyone else from taking control of the robot without his/her knowledge. Hold-to-run function The hold-to-run function allows movement when a button connected to the function is actuated manually and immediately stops any movement when released. The hold-to-run function can only be used in manual mode. How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. Product manual - IRC5 27 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.2.3 Enabling device and hold-to-run functionality

Overview Recovering from an emergency stop is a simple but important procedure. This procedure ensures that the robot system is not returned to production while maintaining a hazardous condition. Reset the latch of emergency stop buttons All push-button style emergency stop devices have a latching feature that must be released in order to remove the emergency stop condition of the device. In many cases this is done by twisting the push-button as marked, but there are also devices where you pull the button to release the latch. Reset automatic emergency stop devices All automatic emergency stop devices also have some kind of latching feature that must be released. Consult your plant or cell documentation to see how your robot system is configured. Recover from emergency stops Action Make sure the hazardous situation that resulted in the emergency stop condition no longer exists. 1 Locate and reset the device or devices that gave the emergency stop condition. 2 Press the Motors On button to recover from the emergency stop condition. 3 28 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.2.4 Recover from emergency stops

General All normal service work; installation, maintenance and repair work, is usually performed with all electrical, pneumatic and hydraulic power switched off. All manipulator movements are usually prevented by mechanical stops etc. Troubleshooting work differs from this. While troubleshooting, all or any power may be switched on, the manipulator movement may be controlled manually from the FlexPendant, by a locally running robot program or by a PLC to which the system may be connected. Dangers during troubleshooting This implies that special considerations unconditionally must be taken when troubleshooting: • All electrical parts must be considered as live. • The manipulator must at all times be expected to perform any movement. • Since safety circuits may be disconnected or strapped to enable normally prohibited functions, the system must be expected to perform accordingly. Product manual - IRC5 29 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.2.5 Safety during troubleshooting

1.3.1 Safety risks during installation and service work on robots Requirements on personnel Only persons who know the robot and are trained in the operation and handling of the robot are allowed to maintain the robot. Persons who are under the influence of alcohol, drugs or any other intoxicating substances are not allowed to install, maintain, repair, or use the robot. • Those in charge of operations must make sure that safety instructions are available for the installation in question. • Those who install or service/maintain the robot must have the appropriate training for the equipment in question and in any safety matters associated with it. • Personnel should be trained on responding to emergency or abnormal situations. General risks during installation and service The instructions in the product manual must always be followed. Never turn the power on to the robot before it is properly fixed and bolted to its foundation/support. Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to always lock the main switch on the controller cabinet with a safety lock. Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to remove the power cable to the controller. If the robot is installed at a height, hanging, or other than standing directly on the floor, there may be additional risks than those for a robot standing directly on the floor. Energy stored in the robot for the purpose of counterbalancing certain axes may be released if the robot, or parts thereof, are dismantled. Never use the robot as a ladder, which means, do not climb on the controller, motors, or other parts during service work. There is a risk of slipping because of the high temperature of the motors and oil spills that can occur on the robot. There is also a risk of the robot being damaged. To avoid damaging the product, make sure that there are no loose screws, turnings, or other parts inside the product after work has been performed. Safety risks during operational disturbances Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. Continues on next page 30 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.3.1 Safety risks during installation and service work on robots

than those associated with regular operation. Such an interruption may have to be rectified manually. Spare parts and special equipment ABB does not supply spare parts and special equipment which have not been tested and approved by ABB. The installation and/or use of such products could negatively affect the structural properties of the robot and as a result of that affect the active or passive safety operation. ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot. Connection of external safety devices Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. An external safety function can interact with other machines and peripheral equipment via this interface. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot. Personal protective equipment Always use suitable personal protective equipment, based on the risk assessment for the installation. Allergenic material See Environmental information on page298 for specification of allergenic materials in the product, if any. Product manual - IRC5 31 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.3.1 Safety risks during installation and service work on robots Continued

Voltage related risks, general Work on the electrical equipment of the robot must be performed by a qualified electrician in accordance with electrical regulations. Although troubleshooting may, on occasion, need to be carried out while the power supply is turned on, the robot must be turned off (by setting the main switch to OFF) when repairing faults, disconnecting electric leads, and disconnecting or connecting units. The main supply to the robot must be connected in such a way that it can be turned off from outside the working space of the robot. Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to always lock the main switch on the controller cabinet with a safety lock. The necessary protection for the electrical equipment and robot during installation, commissioning, and maintenance is guaranteed if the valid regulations are followed. Voltage related risks, IRC5 controller A danger of high voltage is associated with, for example, the following parts: • Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the controller. • Units such as I/O modules, can be supplied with power from an external source. • The main supply/main switch • The transformers • The power unit • The control power supply (230 VAC) • The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: capacitors!) • The drive unit (400/700 VDC) • The drive system power supply (230 VAC) • The service outlets (115/230 VAC) • The customer power supply (230 VAC) • The power supply unit for additional tools, or special power supply units for the machining process. • The external voltage connected to the controller remains live even when the robot is disconnected from the mains. • Additional connections. Voltage related risks, manipulator A danger of low voltage is associated with the manipulator in: • The power supply for the motors (up to 800 VDC). • The user connections for tools or other parts of the installation (max. 230 VAC). Continues on next page 32 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.3.2 Risks associated with live electric parts

Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. Product manual - IRC5 33 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.3.2 Risks associated with live electric parts Continued

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 Note Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor- rectly. Use a wrist strap. The wrist strap button is located inside the control- ler. 1 The mat must be grounded through a current-limit- ing resistor. Use an ESD protective floor mat. 2 The mat should provide a controlled discharge of static voltages and must be grounded. Use a dissipative table mat. 3 34 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.3.3 The unit is sensitive to ESD

Description The cabinet door must be closed properly when the robot system is in production. If a door is not properly closed, the cabinet does not comply with the protection class. The shield for electro magnetic compatibility (EMC) is also affected if the door is not properly closed. Note To comply with IP54 all openings to the controller cabinet must be covered. This includes unconnected connectors which must be fitted with covers. Product manual - IRC5 35 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.3.4 Close the cabinet door

Description Units and heat sinks are hot after running the robot. Touching the units and heat sinks may result in burns. With higher environment temperature more surfaces on the controller get hot and may result in burns. 36 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.3.5 Hot components in controller

Description The key for the mode selector on the IRC5 controller is designed to work with all mode switches on all IRC5 controllers, unless unique keys are ordered. To prevent misuse, it is the responsibility of the robot owner to make sure that all keys only are accessible to authorized personnel. Product manual - IRC5 37 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.3.6 Make sure that all mode selector keys are kept safe

Note Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 38 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.3.7 Risk of disabling function "Reduced speed 250 mm/s"

1.4.1 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 danger level (DANGER, WARNING, or CAUTION) and the type of danger. • A brief description of what will happen if the the danger is not eliminated. • Instruction about how to eliminate danger to simplify doing the work. Danger levels The table below defines the captions specifying the danger levels used throughout this manual. Significance Designation Symbol Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height, and so on. DANGER Warns that an accident may occur if the instructions are not followed that can lead to serious injury, pos- sibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height, etc. WARNING Warns for electrical hazards which could result in severe personal injury or death. ELECTRICAL SHOCK Warns that an accident may occur if the instructions are not followed that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, im- pact, fall from height, etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment where there is a risk of damaging the product or causing a breakdown. CAUTION Warns for electrostatic hazards which could result in severe damage to the product. ELECTROSTATIC DISCHARGE (ESD) Continues on next page Product manual - IRC5 39 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.4.1 Safety signals in the manual

NOTE Describes where to find additional information or how to do an operation in an easier way. TIP 40 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.4.1 Safety signals in the manual Continued

Introduction to labels 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 safety and health symbols on the labels on the product must be observed. Additional safety information given by the system builder or integrator must also be observed. Types of labels Both the manipulator and the controller are marked with several safety and information labels, containing important information about the product. The information is useful for all personnel handling the robot, for example during installation, service, or operation. The information labels can contain information in text (English, German, and French). Symbols on safety labels Description Label Electrical shock xx1400001151 ESD sensitive components inside the controller. xx1400001162 Disconnect power supply before servicing the controller. xx1400001161 Disconnect power supply before servicing the controller (only for welding equipment). xx1400001160 Disconnect power supply before servicing the controller (for controllers without UL mains switch). xx1700000354 Continues on next page Product manual - IRC5 41 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.4.2 Safety symbols on controller labels

the OFF position. xx1400001156 Lifting instruction for the IRC5 controller. xx1400001157 Required installation space. xx1400001155 QR code for ABB Basic Care service agreement. xx1400001154 Continues on next page 42 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.4.2 Safety symbols on controller labels Continued

xx1400001152 Electrical safety check of the robot system (internal). xx1400001158 Functional test of the robot system (internal). xx1400001159 Rating label xx1400001163 CE label xx1800000835 Continues on next page Product manual - IRC5 43 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.4.2 Safety symbols on controller labels Continued

xx1400002060 UL certified (robot with controller) xx1400002061 SafeMove label (for SafeMove Basic and SafeMove Advanced software). xx1700000355 Safety UL label (for the Functional Safety solution together with UL mark). xx1700000353 44 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 1 Safety 1.4.2 Safety symbols on controller labels Continued

2.1 Overview General The ABB IRC5 controller has all components in one cabinet. xx1300000607 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. Wrist strap button The location of the wrist strap button is shown in the following illustration. Continues on next page Product manual - IRC5 45 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.1 Overview

A 46 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.1 Overview Continued

Prerequisites The following section details the main steps on how to unload, transport, install, and connect the IRC5 controller Installing the controller Detailed in Action How to lift, unpack and transport the IRC5 controller is detailed in section Lifting the controller cabinet on page48 and Unpack- ing the controller on page 49 Unpack the IRC5 controller. 1 Bolting down the controller on page 52 Install the IRC5 Controller. 2 Connecting the manipulator to the control- ler on page 73 Connect the manipulator to the IRC5 con- troller. 3 Connecting power supply to the controller on page 68 Connect power supply to the IRC5 control- ler. 4 Connecting a FlexPendant on page 76 Connect the FlexPendant to the IRC5 controller. 5 How to connect MOTORS ON/MOTORS OFF circuits is detailed in section The MOTORS ON/MOTORS OFF circuit on page 88. Miscellaneous connections. 6 How to connect to an external safety relay is detailed in Connection of external safety relay on page 94. How to connect buses, for example Devi- ceNet, is detailed in the respective applic- ation manual. How to connect I/O units to the IRC5 con- troller is detailed in section Installation of DeviceNet I/O, Gateways and encoder in- terface units, IRC5 on page 130. 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 80. Installation of add-ons on page 121 Install add-ons (optional). 7 Product manual - IRC5 47 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.2 Installation activities

2.3.1 Lifting the controller cabinet Lifting device Use the two lifting eyes or a fork lift when lifting the IRC5 controller, as shown below. The following figure shows the maximum angle between the lifting straps when lifting the controller. The weight of the controller module is detailed in section Unpacking the controller on page 49. xx0500001847 48 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.3.1 Lifting the controller cabinet

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: Value Parameter -25°C (-13°F) Min. ambient temperature +55°C (+131°F) Max. ambient temperature +70°C (+158°F) Max. ambient temperature (short periods, max 24 h) Maximum 95% at constant temperature. Max. ambient humidity After storage, the operating conditions must be met for at least 4 hours before switching on the controller (see Operating conditions on page 49 below). Operating conditions The table below shows the allowed operating conditions for the IRC5 controller: Value Parameter 0°C (32°F) Min. ambient temperature +45°C (113°F) Max. ambient temperature +52°C (125.6°F) Max. ambient temperature (option) Maximum 95% at constant temperature. Max. ambient humidity Weight of controller The table below shows the weight for the IRC5 controller: Weight Part Controller max. 150 kg Complete controller IRC5 100-130 kg Extra drive module Continues on next page Product manual - IRC5 49 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.3.2 Unpacking the controller

FlexPendant: Protection class Equipment IP54 IRC5 controller electronics IP33 IRC5 controller air cooling ducts IP54 FlexPendant 50 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.3.2 Unpacking the controller Continued

2.4.1 Required installation space, IRC5 Controller Dimensions The figure below shows the required installation space for the IRC5 controller. xx0500001848 Note The free space on the right hand side of the controller is required to allow opening the door a full 180° and to access the optional moist dust filter. Note The air distance 300 mm on the back of the controller is required to allow inspection and replacement of the optional moist dust filter and ensure proper cooling. Note Do not place customer cables over the moist dust filters on the back of the controller. This makes it difficult to inspect and replace the moist dust filters. Product manual - IRC5 51 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.4.1 Required installation space, IRC5 Controller

Bolt pattern The figure below shows the bolt pattern for the IRC5 controller. The diameter of the four bolt holes are 14 mm. xx0500001853 52 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.4.2 Bolting down the controller

General During transportation the connector cover is secured with two screws. The two screws must be removed before removal of the plate and connection of cables. The screws are located as shown in the illustration below. xx0500002038 Product manual - IRC5 53 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.4.3 Transportation screws

Location The placement of the FlexPendant holder is shown in the illustration below. xx0500002542 FlexPendant holder mounted on top of the control cabinet. A FlexPendant holder mounted on the control cabinet door. B Note In order to avoid drop of the FlexPendant from high levels, the location of the FlexPendant holder on top of the control cabinet is recommended only with one single cabinet without additional drive modules. Otherwise according to location on the control cabinet door. Note Do not position the FlexPendant holder so that it is an obstacle in the place of work. Required equipment Note Equipment The contents are defined in section, Standard toolkit, IRC5 on page 305 Standard tool kit For spare parts, see Miscellaneous parts on page 312. FlexPendant holder Continues on next page 54 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.4.4 Mounting the FlexPendant holder

The following procedure details how to mount the FlexPendant holder on top of the control cabinet. Note/illustration Action xx0500002546 Remove the protective liner from the tape. 1 Press the mounting plate with FlexPendant holder against the top of the control cabinet. Note The surface must be clean and dry. 2 xx0700000240 Mount the cable bracket holder on the side of the cabinet. Use one of the existing M8 screws. 3 • A: Cable bracket holder xx0700000241 Mount the cable bracket on the cable bracket holder using enclosed Fastite screws (4 pcs). 4 • A: Cable bracket Continues on next page Product manual - IRC5 55 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.4.4 Mounting the FlexPendant holder Continued

The following procedure details how to mount the FlexPendant holder on the control cabinet door. Note/Illustration Action xx0800000048 At assembly of FlexPendant holder on the mounting plate start with fasten the Fastite screws (2 pcs) to the mounting plate. 1 • A: Fastite screw (2 pcs) xx1100000052 Fasten the two hooks on the mounting plate with two Fastite screws for each hook. 2 xx1700001453 Mount the FlexPendant holder and cable bracket to the mounting plate with the enclosed Fastite screws (6 pcs). Note Remove the metal sheet plate from the FlexPendant holder before attaching the holder on to the mounting plate. 3 • A: Cable bracket • B: FlexPendant holder • C: FlexPendant metal sheet plate Continues on next page 56 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.4.4 Mounting the FlexPendant holder Continued

is clean and dry. 4 Remove the protective liner from the tape on the mounting plate. 5 xx0700000243 Hitch the hooks around the top of the cabinet door and then press the mounting plate against the door. 6 Product manual - IRC5 57 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.4.4 Mounting the FlexPendant holder Continued

General The following section describes the connectors on the front panel of the IRC5 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 controller. M xx0500001852 Description XP.0 Mains connection A Earth connection point B XS.1 Robot power connection C XS.7 Additional axes power connection D XS.13/XS.5 Customer power/signals external connection E XS.10 Customer options F XS.11 Customer options G XS.12 Customer options H X3 Customer safety signals J XS.28 Network connection K XS.41 Additional axes SMB connection L XS.2 Robot SMB connection M 58 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.1 Connectors on 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. Description Signal class Supplies external motors and brakes. Power signals 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. Class 4 (noisy) Digital operating and data signals (digital I/O, protective stop, etc.). Control signals Applies to cables carrying slightly interfering signals: AC power 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. Class 3 (slightly noisy) Analog measuring and control signals (resolver and analog I/O). Measuring signals This class covers ordinary analogue signals such as analogue sig- 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. Class 2 (slightly sens- itive) Gateway (fieldbus) connection, computer link. Data communication signals Applies to cables carrying very sensitive signals. Signals with a full- 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. Class 1 (sensitive) 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: Cable type Signal class Shielded cable with an area of at least 0.75 mm² or AWG 18. Power signals Shielded cable. Control signals Shielded cable with twisted pair conductors. Measuring signals Shielded cable with twisted pair conductors. A specific cable should be used for field bus connections and Ethernet, according to the standard specification of the respective bus. Data communication signals Continues on next page Product manual - IRC5 59 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.2 Connecting cables to the controller

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. All signals that are sensitive to interference should be routed and strapped along the right side of the controller cabinet according to the image. xx1300000853 Continues on next page 60 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.2 Connecting cables to the controller Continued

laid separate from control, measuring, and communication 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 would also be a risk of overheating depending on the load. Power signals • These signals are very sensitive to interference. To protect these signals they should not be laid along with the power signals. • In the cable, each signal must be twisted with a neutral wire. • The shielding must be connected directly to the chassis at both ends of the cable. Control signals Measuring signals Data communication signals 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. • 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. Continues on next page Product manual - IRC5 61 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.2 Connecting cables to the controller Continued

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 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 10 mm2 copper (AWG7) in the IRC5 controller and 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 controller cabinet, see Connecting power supply to the controller on page 68. For information on how to install the ground for the manipulator, see the corresponding product manual. Continues on next page 62 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.2 Connecting cables to the controller Continued

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. Continues on next page Product manual - IRC5 63 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.2 Connecting cables to the controller Continued

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. 0 V +24 V DC 1) 2) 3) 0 V +24 V AC/DC 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). 64 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.2 Connecting cables to the controller Continued

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. Type of ground connection First letter Direct connection of one point to ground. T Not connected to ground or connected to ground via a high impedance. I Connection between ground and the device being supplied Second letter Direct connection of one point to ground. T Direct connection to neutral at the origin of installation, which is connec- ted to the ground N 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−C system TN−S system A combined PEN conductor is used as both a PE and an N conductor. PE and N are separate conductors that are connected together only near the transformer. L1 L2 L3 PEN xx1700001311 L1 L2 L3 N PE xx1700001310 Not recommended power supply systems The following systems are not recommended by ABB: Resistance grounded secondary system TT system (separate ground rods) If this kind of system must be used, the voltage variations between any line and PE should not exceed ±10% of the nominal line voltage, for more information refer to EN 50160. If this kind of system must be used, the grounding path resistance between ground 1 and 2 shall not exceed 0.1 Ohm, for more information refer to UL1740. Continues on next page Product manual - IRC5 65 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.3 Power supply system requirements

TT system (separate ground rods) L1 L2 L3 N xx1700001313 L1 L2 L3 N xx1700001312 Not allowed power supply systems The following systems are not allowed by ABB: IT system (ungrounded secondary) Un-symmetric system The voltage between phases and ground is undefined and may cause damage to both drive system and mains line filter (if installed). These transformers provide un-symmetric phase voltages with respect to ground. Inher- ent phase imbalances with respect to ground would put the drive system and mains line filter (if installed) under unacceptable stress. xx1700001317 L1 L2 L3 xx1700001316 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 66. • 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, see below. • Mains power supply is out of standard limits, like voltage variations (+10% to -15%), frequency variations (48.5 Hz to 61.8 Hz), harmonic (5%), voltage unbalance (2%), voltage surge, voltage dips/swells, and so on. Continues on next page 66 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.3 Power supply system requirements Continued

Allowed isolation transformer types The following isolation transformer types are allowed by ABB: Wye-Wye isolation transformer (Y /Y) Delta-Wye isolation transformer (△/Y) xx1700001319 xx1700001318 A Primary/input B Secondary/output Mains line filter The IRC5 controller option 129-1 Prepared for CE labelling consists of a mains line filter (3HAC024322-001) to prevent emissions to the incoming power. A mains line filter in each robot cabinet is required for any of the below conditions: • Robot system CE-labelling is required. • Robot system will be installed in an EU country. • 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, see below. • Mains power supply is out of standard limits, like voltage variations (+10% to -15%), frequency variations (48.5 Hz to 61.8 Hz), harmonic (5%), voltage unbalance (2%), voltage surge, voltage dips/swells, and so on. Other types of external filters may be used, provided they are approved by regional standards. For further information refer to regional power supply standards. Product manual - IRC5 67 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.3 Power supply system requirements Continued

Location of power supply connection xx0500001869 Cable gland A Rated voltage and current To find the rated voltage, rated current and Short Circuit Current Rating of the controller, see the name plate on the side of the cabinet. The illustration shows an example of lable position. xx0900000273 Controller name plate A Ampere Short Circuit Current Rating (SCCR) 10 KA UL/CSA 6.5 KA EU(IEC) Continues on next page 68 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.4 Connecting power supply to the controller

Americas and some Asian countries) voids warranty. If the facility has a substation with any type of delta connection, a grounded Y-configured transformer must be installed before the robot controller. Line fusing Recommended line fusing, slow-blowing diazed or circuit breaker with trip characteristic K. Max. fuse 35 A, with options 80 A. Description Voltage Robot 3x16 A at 400-660 V IRB 120, 1200, 140, 1410, 1600, 2400, 2600, 260, 360, 4400 3x16 A at 200-220 V IRB 120, 1200, 140, 1410, 1600, 2400, 2600, 260, 360, 4400 3x25 A at 400-600 V IRB 4600, 660, 460, 760, 66XX, 6700, 7600, 8700 3x35 A at 200-220 V IRB 660, 66XX, 6700, 760, 7600, 8700 3x35 A at 200-220 V IRB 4600, 660, 460, 760, 66XX, 6700, 7600, 8700 Transformer For information about included servo transformer, see Product specification - Controller IRC5. Note that not all voltage levels are available for all transformers, but the voltage tolerance is -15%...+10%. Note If another voltage is used than the one specified on the controller name plate, this should be replaced so the name plate has the correct information. Prerequisites Note Equipment Power supply cable (3-phase) For control cables up to 7m, a 30mA earth fault protection can be used if it is Hager CDH440R or equal residual current circuit breaker. External earth fault protection (residual current circuit breaker, Class B for frequency converters, 300mA) The contents are defined in sec- tion Standard toolkit! Standard toolkit These procedures include refer- ences to the tools required. Other tools and procedures may be required. See refer- ences to these procedures in the step-by-step instruc- tions below. See Circuit diagrams on page325. Circuit diagram Continues on next page Product manual - IRC5 69 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.4 Connecting power supply to the controller Continued

The following procedures detail how to connect the mains power to the controller through a cable gland. Note/illustration Action Prerequisites on page 69 Connect power supply from an external earth fault protection. 1 xx0500001870 Fit the cable trough the cable gland and tighten. 2 Parts: • A: cable gland • B: rotary switch • C: cable pipe • D: grounding point Continues on next page 70 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.4 Connecting power supply to the controller Continued

cable long enough to reach the rotary switch. 3 See illustration in step 2. Connect the ground cable at the ground- ing point. 4 Tightening torque, 4.5 Nm. See illustration in step 2. Route the phase wires through the pipe up to the rotary switch. 5 For three phase: xx0500001882 Connect the wires as shown in the illus- tration. 6 For single phase: xx1100000019 For single phase, pin 5 is plugged. Connection through a connector The following procedures detail how to connect the mains power to the controller through a connector. CAUTION Always inspect the connector for dirt or damage before connecting it to the controller. Clean or replace any damaged parts. Continues on next page Product manual - IRC5 71 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.4 Connecting power supply to the controller Continued

supply to connector XP0 on the front panel on the controller. 1 Parts: • A: XP0 Mains power connector 72 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.4 Connecting power supply to the controller Continued

General Connect the manipulator and the controller to each other after installing them. The lists below specify which cables to be used in each application. All connectors on the controller are shown in section Connectors on the controller on page 58. Main cable categories All cables between the manipulator and the controller are divided into the following categories: Description Cable category Handles power supply to and control of the manipulator's motors as well as feedback from the serial measurement board. Manipulator cables Handles supply to and feedback from any position switches. Position switch cables (option) Handles communication with equipment fitted on the manipulator by the customer. Customer cables (option) Handles power supply to and control of the external axes motors as well as feedback from the servo system. Additional axes cables (option) These categories above are divided into sub-categories which are specified in section Manipulator cables on page 314. Product manual - IRC5 73 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.5 Connecting the manipulator to the controller

External customer connection If the cabinet is equipped with the option external customer connection, connect the connector as shown in the following illustration. CAUTION Always inspect the connector for dirt or damage before connecting it to the controller. Clean or replace any damaged parts. A xx1300000601 External customer connection of safety signals. A Continues on next page 74 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.6 Connecting safety signals

If the cabinet is not equipped with the option external customer connection, the signal cables must go though a cable gland and be connected to the panel board inside the cabinet. xx1000000141 Cable gland A Note The signal cable should be shielded and the shielding connected to the cable gland, or a ferrite ring should be used around the cable inside the cabinet close to the cable gland. The same goes for all customer I/O signals. Product manual - IRC5 75 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.6 Connecting safety signals Continued

Location of FlexPendant connector The FlexPendant connector on the IRC5 controller is located on the operator’s panel on the controller, or on an external operator’s panel. CAUTION Always inspect the connector for dirt or damage before connecting it to the controller. Clean or replace any damaged parts. xx0600002782 FlexPendant connector (A22.X1) L Connecting a FlexPendant Information Action The controller must be in manual mode. If your system has the option Hot plug, then you can also disconnect in auto mode. See section Using the hot plug option on page 77. Locate the FlexPendant socket connector on the controller or operator’s panel. 1 Plug in the FlexPendant cable connector. 2 Screw the connector lock ring firmly by turning it clockwise. 3 76 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.7 Connecting a FlexPendant

Hot plug option The hot plug option makes it possible to: • Disconnect the FlexPendant from a system in automatic mode and thereby run the system without a FlexPendant connected. • Temporarily connect and operate a FlexPendant without interrupting the application running on the system. WARNING Pressing the hot plug button disables the emergency stop button on the FlexPendant. Only press the hot plug button while connecting or disconnecting the FlexPendant. WARNING A disconnected FlexPendant must always be stored separated from the IRC5 controller! Connect and disconnect the FlexPendant using the hot plug button The following procedure describes how to connect or disconnect the FlexPendant on a system in automatic mode using the hot plug button option. Note Do not switch to manual mode (or manual full speed mode) while the system is running without the FlexPendant. The FlexPendant must be connected when you switch to automatic mode otherwise you cannot confirm the mode change. Information Action Make sure that the system is in automatic mode. 1 A red lamp inside the button indicates when pressed. Press and hold the hot plug button. 2 Continues on next page Product manual - IRC5 77 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.8 Using the hot plug option

the same time, switch the jumper plug with the FlexPendant plug. 3 A: Hot plug button B: FlexPendant connector xx0600002796 Jumper plug Make sure that the button is not stuck in the actuated position since this disables the FlexPendant emergency stop button. Release the hot plug button. 4 Note When the FlexPendant is disconnected, the jumper plug must be connected in its place. Note If the hot plug button is released while neither the jumper plug, nor the FlexPendant is connected, the robot movements will be stopped since the emergency stop chains are opened. Limitations for messages on the FlexPendant When using the hot plug option, the following limitations apply to messages on the FlexPendant: Operator messages Some applications may require input from the operator by using the FlexPendant (e.g. applications using RAPID instructions TPReadNum, UIMsgBox, etc.). If the application encounters such an operator message, program execution will wait. After connecting the FlexPendant you must then stop and start the program execution to be able to see and respond to these messages. They are not displayed automatically by just connecting the FlexPendant. If possible, avoid using these types of instructions when programming systems that are using the hot plug button option. Continues on next page 78 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.8 Using the hot plug option Continued

When connecting the FlexPendant, event log messages can be viewed also for the period when the FlexPendant was disconnected, since these are stored on the controller. Product manual - IRC5 79 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.8 Using the hot plug option Continued

Overview of the computer unit The following illustration shows an overview of the computer unit. xx1300000608 Power supply X1 Service (connection of PC). X2 (yellow) LAN1 (connection of FlexPendant). X3 (green) LAN2 (connection of Ethernet based options). X4 LAN3 (connection of Ethernet based options). X5 WAN (connection to factory WAN). X6 Panel unit X7 (blue) Axis computer X9 (red) USB ports (4 ports) X10, X11 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 80 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.9 Connectors on the computer unit

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: • 192.168.125.0 - 255 • 192.168.126.0 - 255 • 192.168.127.0 - 255 • 192.168.128.0 - 255 • 192.168.129.0 - 255 • 192.168.130.0 - 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. Continues on next page Product manual - IRC5 81 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.9 Connectors on the computer unit Continued

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. WAN LAN 2 LAN 3 Private Robot Controller LAN 1 Service Public Isolated LAN 3 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. WAN LAN 2 LAN 3 Private LAN 1 Service Public Robot Controller 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 USB1 and USB2 on the X10 connector for connecting USB memory devices. The USB ports on the X11 connector are intended for internal use. 82 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.9 Connectors on the computer unit Continued

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 114. Location The serial channel connector is located on the expansion board in the computer unit as shown below. B A xx1300000610 COM1 A CONSOLE B Note The CONSOLE connector is used for debugging purposes only. Continues on next page Product manual - IRC5 83 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.10 Connecting a serial channel to the controller

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. Info/Illustration Action A cable is needed between the serial channel connector and the adapter. A B xx1300000854 A cable B adapter Connect the adapter to the serial channel connector. 1 84 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.10 Connecting a serial channel to the controller Continued

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 category configuration The stop category can be configured, see Technical reference manual - System parameters. Description System paramet- er Function Safety inputs 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). SoftAS Automatic Stop 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). SoftGS General Stop 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). SoftSS Superior Stop SoftES is used to configure the emergency stop in automatic and manual mode. The default configuration is FALSE (stop category 0). SoftES Emergency Stop Note When an input to initiate an automatic stop (SoftAS) is activated, it must remain active for at least 1.5 s. 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 networks, I/O blocks, RobAPI, etc. See Application manual - Controller software IRC5. Description Pre-defined system input The RAPID program execution is stopped, and the manipulator is stopped on path with no deviation. The RAPID program cannot be started when this system input signal is high. This stop is similar to a normal program stop using stop button on the FlexPendant. Stop 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. SoftStop Continues on next page Product manual - IRC5 85 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.11 Programmable stop functions

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. QuickStop 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 Cycle Stops program execution after the current instruction is com- pleted. Stop at End of Instruction 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. Note Only safety rated input signals are allowed to be used for safety. Stop with RAPID instructions There are several RAPID instructions available that stops the robot. Arguments Description Instruction \Stop: similar to a normal pro- gram stop with stop button. Stops all robots in all tasks imme- diately. SystemStopAction \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. \NoRegain: the robot will not re- turn to the stop point when restar- ted, e.g. after having been jogged away. The current move instruction will be finished before the robot stops. A restart will continue the program execution. Stop \AllMoveTasks: all robots will be stopped. \Quick: the stop will be a soft stop on path, as described for system input SoftStop, otherwise similar to a normal program stop. The current move instruction will be stopped immediately as a nor- mal program stop but the program execution will continue with the next instruction. This is often used in for example trap routines. StopMove \AllMotionTasks: all robots will be stopped. 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. BREAK Continues on next page 86 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.11 Programmable stop functions Continued

the program execution will be stopped immediately as a normal program stop. After stop the Pro- gram Pointer has to be reset to Main. EXIT The current move instruction and program execution will be stopped immediately. The Program Pointer will be reset to Main and if running mode is continuous, the program will be restarted. EXITCYCLE \Stop: the robot will stop as fast as possible. This stop is per- formed by ramping down motion in each motor separate from each other, and as fast as possible. Since it will be without any coordin- ation, the robot may slide off path fairly much. Search instructions can be pro- grammed with arguments to stop the robot movement close to the point where a search hit was no- ticed. The program execution will continue with the next instruction. SearchX \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 valid for IRC5 are described in Technical reference manual - RAPID Instructions, Functions and Data types. Other unexpected stops Description Type of stop 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. SysFail In the control system there is a monitoring function that can detect power failure. In such cases a stop will be initiated. Power fail 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 movement when restarted. Stop at collision WARNING The revolution counters might need to be updated after a colli- sion to ensure path accuracy. Product manual - IRC5 87 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.11 Programmable stop functions Continued

Outline diagram The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of switches. The diagram shows the available customer connections, AS, GS, SS and ES. A & N O P R D E F G M H C C B J K L S T xx0100000174 ES (emergency stop) A LS (Limit switch) B Solid state switches C Contactor D Mains E Drive unit F Second chain interlock G GS (general mode safeguarded space stop) H SS (superior stop, same function as GS) J AS (Automatic mode safeguarded space stop) K ED (FlexPendant three-position enabling device) L Manual mode M Automatic mode N Operating mode selector O RUN P EN1 R Continues on next page 88 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.12 The MOTORS ON/MOTORS OFF circuit

Function of the MOTORS ON/MOTORS OFF circuit The circuit monitors all safety related equipment and switches. If any of the switches is opened, the MOTORS ON/MOTORS OFF circuit switches the power to the motors off. As long as the two chains not are in an identical state, the robot will remain in MOTORS OFF mode. Continues on next page Product manual - IRC5 89 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.12 The MOTORS ON/MOTORS OFF circuit Continued

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. Terminal Location X5, X6 X22, X24 Control Module Drive Module xx0100000166 Technical data per chain Load: 300 mV Limit switch Max. voltage drop: 1 V Load: 10 mA External connectors Max. voltage drop: 4 V 25 mA GS/AS/SS load at 24 V >18 V GS/AS/SS closed "1" < 5 V GS/AS/SS open "0" Max. + 35 VDC External supply of GS/AS/SS Min. - 35 VDC 2.0 ms i GS/AS/SS Filter time Continues on next page 90 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.12 The MOTORS ON/MOTORS OFF circuit Continued

300 V Max. potential in relation to the cabinet earthing and other signal groups. Control signals Signal class i When connecting for example a safety PLC to a safety stop, make sure that the safety check pulses not exceeds 2.0 ms, otherwise a safety relay must be connected in between. See the following illustration. xx0800000130 Connection of ES1/ES2 on panel unit Note The diagram below shows the terminals for the emergency circuits for a controller without safety module (option 996-1). For a controller with a safety module, status signals for emergency stop can only be read from the safe fieldbus (see Application manual - Functional safety and SafeMove2). Continues on next page Product manual - IRC5 91 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.12 The MOTORS ON/MOTORS OFF circuit Continued

ext. supply, X1:3 / X2:7 is connected to ext. 24V, and X1:7 / X2:3 is connected to ext. 0V. 24V 24V 0V 0V X1:4 X1:8 X1:3 X1:7 X1:9 X1:10 X1:1 X1:2 24V A B C D D X1:6 E 24V X2:9 X2:10 X2:1 X2:2 0V X2:6 F B 0V X2:4 X2:5 C X2:4 G H J X2:3 X2:8 X2:7 X1:4 X1:5 ES1 ES2 xx0100000191 Internal A Ext stop B FlexPendant C Cabinet D ES1 internal E Run chain 1 top F Internal G ES2 internal H Run chain 2 top J Emergency stop output 1 ES1 Emergency stop output 2 ES2 Technical data 120 VAC or 48 VDC ES1 and ES2 max output voltage Continues on next page 92 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.12 The MOTORS ON/MOTORS OFF circuit Continued

ES1 and ES2 max output current 48 VDC L/R: 50 mA 24 VDC L/R: 2 A 24 VDC R load: 8 A 24 VDC ± 10% between terminals X1:3, 7 and X2:7, 3 respectively. Note In case of interference, the external sup- ply must be properly filtered. External supply of ES relay 40 mA Rated current per chain 300 V Max. potential in relation to the cabinet earthing and other signal groups. Control signals Signal class Connection to operating mode selector The illustration below shows the connection of terminals for customer use. xx0500002092 Mode selector A Technical data 48 VDC Max. voltage 4 A Max. current 300 V Max. potential in relation to the cabinet earthing and other signal groups. Control signals Signal class Product manual - IRC5 93 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.12 The MOTORS ON/MOTORS OFF circuit Continued

Description The motor contactors K42 and K43 in the controller can operate with external equipment if external relays are used. Connection example The following figure shows an example of how to connect an external safety relay. xx0100000246 Robot 1 C Robot 2 D ES (emergency stop) relay F External Safety relay G To other equipment H Safety gate J Cell ES (emergency stop) K 94 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.13 Connection of external safety relay

General This section details connection to the MOTORS ON/MOTORS OFF contactor. To be used when the customer wants external equipment to follow the robot control. Location The MOTORS ON/MOTORS OFF contactor is located on the left hand side in the controller. A B C D E xx0400001058 MOTOR ON contactor K42 / K43 A Contactor auxiliary block 33-34 B Brake contactor C Jumper (3 pcs) D Contactor interface board E Required equipment The table below details the required equipment. Note Equipment Standard toolkit See Circuit diagrams on page 325. Circuit diagram Technical data The table below shows technical data. Technical data 48 VDC Max. voltage 4 A Max. current Continues on next page Product manual - IRC5 95 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.14 Connection to MOTORS ON/MOTORS OFF contactor

and other signal groups. Control signals Signal class Procedure Following procedure describes connection to the MOTORS ON/MOTORS OFF contactor. Info/Illustration Action DANGER Before commencing any work inside the cabinet, please observe the safety information in section Make sure that the main power has been switched off on page 26. 1 xx0400001231 Connect the wires to the contactor auxiliary blocks 33-34, accord- ing to the diagram to the right. 2 96 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.14 Connection to MOTORS ON/MOTORS OFF contactor Continued

General A controller that handles several robots or an application that requires more than three external axes needs extra drive modules (one drive module per robot). Up to four drive modules can be used, including the one assembled in the IRC5 controller. This manual only describes the connector interface on the drive module. More information about installation of the drive module with the applications MultiMove can be found in Application manual - MultiMove. Connectors The following details the connectors on the front panel of the drive module. L M N K J H G F C B A D E xx0600002931 Description Power connection to IRC5 controller A A4.X0: Mains connection to transformer B Earth connection point C A4.X1: Robot power connection D A4.X7: External axes power connection E A4.XX: Customer options F A4.XX: Customer options G A4.XX: Customer options H A4.XX: Customer options J Communication cabling between controller/drive module K Communication cabling between controller/drive module L A4.XS41: Additional axes SMB connection M A4.XS2: Robot SMB connection N Product manual - IRC5 97 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.15 Connection of drive module

General This function enables you to temporarily disconnect a drive module and deactivate any robot or additional mechanical units connected to this module. The procedures are detailed below. It is also possible to connect a remote switch to enable a Drive Module Disconnect. The required equipment and procedure for connection of a switch are specified below. Note The system diagnostics monitors the connection and disconnection of drive modules, and event log messages regarding these events will be stored in the event log when required. These messages are accessible using the FlexPendant or RobotStudio. Note This functionality cannot be used together with SafeMove, option 810-2. Continues on next page 98 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.16 Connection of Drive Module Disconnect, by limit switch

as shown below. A B xx1300000855 Contactor interface board A Contactors B Required equipment The table below details the required equipment. Note Equipment AWG20 Wire 24V 0.5A Switch Operating manual - RobotStudio Operating manual - IRC5 with FlexPendant Standard toolkit See Circuit diagrams on page 325. Circuit diagram Continues on next page Product manual - IRC5 99 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.16 Connection of Drive Module Disconnect, by limit switch Continued

The following procedures details how to enable the system for Drive Module Disconnect. Action In the Configuration editor in RobotStudio, select the topic Motion. 1 Select the type Drive Module User Data. 2 Set the parameter for selected drive module to YES. 3 Restart the system. 4 Enabling Drive Module Disconnect with the FlexPendant The following procedures details how to enable the system for Drive Module Disconnect. Action In the Control panel on the FlexPendant, tap Topics, and select Motion. 1 Tap the type Drive Module User Data, and then tap to select the drive module. 2 Set the parameter for selected drive module to YES. 3 Restart the system. 4 Disconnecting the drive module Use this procedure to disconnect a drive module. Note/illustration Action Make sure that the system is in the MO- TORS_OFF state. 1 It is also possible to use connector X21, but this is typically used for limit switches on the robot. xx0500002087 Disconnect the connector X22. 2 Reconnecting the drive module Use this procedure to reconnect the drive module. Note/illustration Action Make sure that the system is in the MO- TORS_OFF state. 1 Continues on next page 100 Product manual - IRC5 3HAC047136-001 Revision: M © Copyright 2004-2018 ABB. All rights reserved. 2 Installation and commissioning 2.5.16 Connection of Drive Module Disconnect, by limit switch Continued