ROBOTICSSafety manual for robotManipulator and IRC5 or OmniCorecontroller

ABB IRC5 Safety Manual

Overview

Safety note

Procedures

Procedure for MultiMove systems

Common procedures for all systems

General

What is a FlexPendant

What is RobotStudio

What is RobotWare

About the media pool

When to use the FlexPendant and RobotStudio

HAC16590

Product documentation, M2004

IRC5 Compact

Safety

General safety information

General Information

Safety risks

Safety actions

Safety stops

What is an emergency stop

What is a safety stop

What is safeguarding

Safety related instructions

DANGER - Make sure that the main power has been switched off

WARNING - The unit is sensitive to ESD

Controller

CAUTION - Hot components in controller

Installation and Commissioning, IRC5

Installation Activities

Transporting and handling

On-site Installation

Connections

Connecting power supply to the IRC5 Panel Mounted Controller

Connecting fan unit to IRC5 Panel Mounted Drive Module

Connecting a FlexPendant

Connecting a PC to the service port

Connection to serial channel connector

The MOTORS ON/MOTORS OFF circuit

Connection of external safety relay

Connection of Drive Module Disconnect, by limit switch

Connecting a Limit switch override push button

Drive system

Configuration of the drive system, IRC5

Memory functions

Connecting a USB memory to the computer unit

I/O system

Installation of add-ons

Installation of additional Drive Module

Installation of external operator's panel, IRC5

Installation of I/O, Gateways and encoder interface units, IRC5

Maintenance activities, controller IRC5

Inspection activities

Changing/replacing activities

Cleaning activities

Cleaning the FlexPendant

Repair activities, controller IRC5

Replacement of panel board

Replacement of power supply

Replacement of customer I/O power supply, IRC5

Replacement of drive system power supply

Replacement of I/O units and Gateways

Replacement of backup energy bank

Replacement of computer unit DSQC639

Replacement of motherboard in computer unit DSQC639

Replacement of DDR SDRAM memory on motherboard in computer unit DSQC639

Replacement of PCI boards in the computer unit DSQC639

Replacement of fieldbus adapter in the computer unit DSQC639

Replacement of fan in computer unit DSQC639

Replacement of Compact Flash memory in computer unit DSQC639

Replacement of servo drive units and rectifier

Replacement of Axis computer

Replacement of Contactor Interface Board

Replacement of drive system fans

Replacement of transformer unit

Replacement of brake resistor bleeder

Reference information, IRC5

Unit conversion

Screw joints

Weight specifications

Standard toolkit, IRC5

Document references

Spare Parts

Manipulator cables

Position switch cables

Customer signal, CS/CP and CS

Customer power-signal

Circuit Diagram

CAUTION - Never stand on or use the cabinet as a ladder

DSQC639

CAUTION - Close the cabinet door

Unpacking, IRC5 Controller

Bolting down the controller

Transportation screws

Mounting the FlexPendant holder

Connecting power supply to the Single Cabinet Controller

Connecting power supply to the Dual Cabinet Controller

Connecting the communication cabling for the Dual Cabinet Controller

Fitting the connector

Connecting the manipulator to the IRC5 controller

Connection to MOTORS ON/MOTORS OFF contactor

Connection of servo disconnect, by servo power switch

Installation of Drive system parts

Installation of PMC-card for Force Control Function

Installation of extra mass memory in computer unit DSQC623

Installation of Euromap and SPI

Upgrading and installation of 2X Euromap interface (Option 671-4)

Installation of cooling fan harness axis 1 and 2

Installation of Hot plug

Installing the EPS board DSQC 646 for Electronic Position Switches

Installing the SafeMove board DSQC 647

Installation of Remote Service

Replacement of moist dust filter

Cleaning moist dust filter

Replacement of power distribution board

Replacement of customer I/O power supply

Replacement of system power supply

Replacement of Flange disconnect

Replacement of control system fan

Replacement of heat exchange unit and fan

Replacement of computer unit DSQC623

Replacement of motherboard in computer unit DSQC623

Replacement of PCI cards in the computer unit DSQC623

Replacement of fan in computer unit DSQC623

Replacement of hard disk or IDE Flash module and cable in computer unit DSQC623

Replacement of computer power supply in computer unit DSQC623

Replacement of servo drive units, rectifierand capacitorunit

Replacement of EPS board DSQC 646

Replacement of SafeMove board DSQC 647

Replacement of Remote Service box

Overview of this manual

Safety in the manipulator system

Risks associated with live electric parts

Safety signals in the manual

CAUTION - Make sure that there are no loose screws or turnings

Installation and commissioning

Unpacking the controller

On-site installation

Vertical mounting

Buttons and switches

Brake release button

Connectors on the IRC5 Compact controller

Connection to serial channel

Connecting power supply

Connecting the manipulator to the IRC5 Compact controller

Descriptions for contacts XS7, XS9, XS10, XS11, XS12 and XS13

Emergency stop output

Opening the IRC5 Compact controller

Accessing the controller parts

Connecting a USB memory

Installation of external operator's panel

Installation of I/O, gateways and encoder interface units outside IRC5 Compact

Installation of Remote Service antenna

Installation of external terminal blocks

Maintenance

Activities

Repair

Replacement of safety board

Replacement of I/O unit

Replacement of motherboard

Replacement of DDR SDRAM memory on motherboard

Replacement of DeviceNet Lean board

Replacement of PCI boards

Replacement of fieldbus adapter

Replacement of Compact Flash memory

Replacement of drive unit

Replacement of axis computer DSQC 668

Replacement of system fans

Replacement of line filter

Decommissioning

Introduction

Reference information

Applicable safety standards

Spare parts

Circuit diagrams

Index

Product documentation

Network security

Safety data

Protective stop and emergency stop

Make sure that the main power has been switched off

Enabling device and hold-to-run functionality

Recover from emergency stops

Safety during troubleshooting

The unit is sensitive to ESD

Close the cabinet door

Hot components in controller

Make sure that all mode selector keys are kept safe

Risk of disabling function "Reduced speed 250 mm/s

Safety signals and symbols

Safety symbols on controller labels

Installation activities

Connecting cables to the controller

Power supply system requirements

Connecting power supply to the controller

Connecting the manipulator to the controller

Connecting safety signals

Using the hot plug option