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Product manual (part 2 of 2), reference information

Robot Controller
IRC5 M2004

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Product manual (part 2 of 2), reference information IRC5


M2004 Document ID: 3HAC021313-001 Revision: A

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The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, 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 ABBs written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this manual may be obtained from ABB at its then current charge.

Copyright 2004 ABB All right reserved. ABB Automation Technologies AB Robotics SE-721 68 Vsters Sweden

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Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 Reference information, IRC5 7

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.6 Standard toolkit, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.7 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2 Spare Parts 17

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.2 Spare Parts IRC5, Control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.3 Spare Parts IRC5, Drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3 Circuit Diagram 23

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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3HAC021313-001

Overview

Overview
About This Manual This manual contains reference information for all procedures described in the Product manual procedures. Usage This manual should be used during: operation, installation... installation maintenance work repair work.

Who Should Read This Manual? This manual is intended for: Prerequisites The reader should... be a trained maintenance/repair craftsman have the required knowledge of mechanical and electrical installation/maintenance/ repair work. installation personnel maintenance personnel repair personnel.

Organization of Chapters The manual is organized in the following chapters: Chapter


Reference information

Contents
Useful information when performing installation, maintenance or repair work (lists of necessary tools, reference documents, safety standards). List of controller spare parts. Circuit Diagram of the controller.

Spare part list Circuit diagram

References See section document references. Revisions Revision


-

Description
First edition

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3HAC021313-001

Product documentation, M2004

Product documentation, M2004


General The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems. Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures Safety information Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software) Maintenance (descriptions of all required preventive maintenance procedures including intervals) Repair (descriptions of all recommended repair procedures including spare parts) Additional procedures, if any (calibration, decommissioning)

Product manual, reference information RobotWare manuals The following manuals describe the robot software in general and contain relevant reference information: RAPID Overview: An overview of the RAPID programming language. RAPID reference manual part 1: Description of all RAPID instructions. RAPID reference manual part 2: Description of all RAPID functions and data types. Technical reference manual - System parameters: Description of system parameters and configuration workflows. Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards) Part list Foldouts or exploded views Circuit diagrams

Application manuals Specific applications (e.g. 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:
3HAC021313-001

The purpose of the application (what it does and when it is useful) What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
A 5

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Product documentation, M2004

Operators manuals

How to use the application Examples of how to use the application

This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters. The group of manuals include: Miscellaneous A number of manuals provide generic descriptions of the robot and robot system. These include: Robot fundamentals (describing the fundamental aspects, functions, concept and similar, of a robot system to provide a basic understanding of the robot system) Operators manual - IRC5 with FlexPendant Operators manual - RobotStudioOnline Trouble shooting Manual for the controller and robot

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3HAC021313-001

1 Reference information, IRC5


1.1. Introduction

1 Reference information, IRC5


1.1. Introduction
General This chapter includes general information, complementing the more specific information in the following chapters.

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3HAC021313-001

1 Reference information, IRC5


1.2. Applicable Safety Standards

1.2. Applicable Safety Standards


Standards, general The robot is designed in accordance with the requirements of: Standards, safety fence The following standards are applicable to the safety fence surrounding the robot cell: Standards, robot cell The following standards are applicable when the robot is part of a robot cell: IEN 294, Safety of machinery - Safety distance to prevent danger zones being reached by the upper limbs. EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human body. EN 811 Safety of machinery - Safety distance to prevent danger zones being reached by the lower limbs. Pr EN 999 Safety of machinery - The positioning of protective equipment in respect of approach speeds of the human body. EN 1088 Safety of machinery - Interlocking device associated with guards principles for design and selection. ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing systems - Basic requirements prEN 999:1995 ISO10218, Jan. 1992, Industrial Robot Safety ANSI/RIA 15.06-1999 ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing systems - Basic requirements DIN 19258 - Interbus-S, International Standard

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3HAC021313-001

1 Reference information, IRC5


1.3. Unit conversion

1.3. Unit conversion


Converter table Use the table below to convert units used in this manual.

Quantity
Length Weight Pressure Force Moment Volume

Units
1m 1 kg 1 bar 1N 1 Nm 1L 3.28 ft 2.21 lb 100 kPa 0.738 lbf 0.738 lbf-tn 0.264 US gal 14.5 psi 39.37 in

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3HAC021313-001

1 Reference information, IRC5


1.4. Screw joints

1.4. Screw joints


General This section details how to tighten the various types of screw joints on the controller. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials. Tightening torque Before tightening any screw, note the following: Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description. Any special torque specified overrides the standard value. Use the correct tightening torque for each type of screw joint. Only use correctly calibrated torque keys. Always tighten the joint by hand, and never use pneumatical tools Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow, flowing motion. Maximum allowed total deviation from the specified value is 10%!

The table below specify the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws.

Dimension
M2.5 M3 M4 M5 M6

Tightening torque (Nm) Class 4.8, oil-lubricated


0.25 0.5 1.2 2.5 5.0

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3HAC021313-001

1 Reference information, IRC5


1.5. Weight specifications

1.5. Weight specifications


Definition In all repair and maintenance instructions, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way. To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. Example Below is an example of how a weight specification is presented: CAUTION! Caution! The transformer weighs 55 kg! All lifting equipment used must be sized accordingly!

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3HAC021313-001

11

1 Reference information, IRC5


1.6. Standard toolkit, IRC5

1.6. Standard toolkit, IRC5


General All service (repair, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools, i.e. all tools that are not considered standard as defined below, are listed in their instructions respectively. This way, the tools required are the sum of the Standard Toolkit and any tools listed in the instruction. Contents Tool
Screw driver, Torx Screw driver, Torx Ball tipped screw driver, Torx Screw driver, flat blade Screw driver, flat blade Screw driver, flat blade Screw driver Box spanner

Remark
Tx10 Tx25 Tx25 4 mm 8 mm 12 mm Phillips-1 8 mm

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3HAC021313-001

1 Reference information, IRC5


1.7. Document references

1.7. Document references


General The contents of this manual may include references to additional documentation necessary to perform certain procedures. This section specifies the article numbers for the referenced documentaion. Product specification, controller The product specification includes generic technical data. The specification listed below is the English version.

Document name
Product Specification - IRC5 with FlexPendant

Document ID
3HAC021785-001

Operators manual The operators manual contains instructions for daily operation of robot systems. The operators manual listed below is the English version.

Document name
Operators manual - IRC5 with FlexPendant

Document ID
3HAC 16590-1

Note

Application documentation Document name


Trouble shooting manual - IRC5 Operators manual - RobotStudio Online

Document ID
3HAC 020738-001 3HAC 18236-1

Getting started - IRC5 and RobotStudio Online 3HAC 021564-001

Product manual, robot The product manuals include information about installation and service activities. The table below specifies the article numbers of the product mnauals for all robot models. The part number -001 is the English version.

Document name
Product manual, IRB 140 Product manual, IRB 1400 Product manual, IRB 2400 Product manual, IRB 4400 Product manual, IRB 6600/6650 type A Product manual, IRB 6600/6650 type B Product manual, IRB 6650S

Document ID
3HAC 021111-001 3HAC 022031-001 3HAC 022032-001 3HAC 020938-001 3HAC 023082-001 3HAC 020993-001

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3HAC021313-001

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1 Reference information, IRC5


1.7. Document references

Document name
Product manual, IRB 7600 Product manual, IRB 940

Document ID
3HAC 022033-001 3HAC 022054-001

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3HAC021313-001

1 Reference information, IRC5


1.8. Lifting equipment and lifting instructions

1.8. Lifting equipment and lifting instructions


General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment. This implies that the instructions delivered with the lifting equipment should be stored for later reference.

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1 Reference information, IRC5


1.8. Lifting equipment and lifting instructions

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3HAC021313-001

2 Spare Parts
2.1. Introduction

2 Spare Parts
2.1. Introduction
Definitions This chapter specifies all spare parts and replacement articles of the IRC5 controller.

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3HAC021313-001

17

2 Spare Parts
2.2. Spare Parts IRC5, Control module

2.2. Spare Parts IRC5, Control module


Control cabinet

xx0400001234

Spare parts Pos


A21

Spare part number


3HAC020665-001 3HAC020901-001 3HAC020901-002 3HAC14605-1 3HAC020586-001 3HAC021009-001 3HNE01586-1 3HAC14944-1 3HAC11819-1 3HAC5579-1 3HAC5577-1 3HNE00009-1 3HNE00006-1 3HAB9715-1 3HAB7342-1 3HAB9743-1 3HAC1836-1 3HAB9664-1 3

Description
Panel Board Unit Control panel 2-pos mode Control panel 3-pos mode Junction board DSQC616 Harness,Panel board/ GTPU Harness-Panel board/Fan u Queue Tracker RS-232/422 converter Interbus slave with Cu InterBus-S adap. Profibus-DP adap Profibus DP Slave unit Interbus-S Unit Multipole con. X1-X4 10p Multipole con.set X7,X8 Multipole con. X1-X4 16p Multipole con. X3 5p Multipole con. X6 6p

Note

DSQC 615

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3HAC021313-001

2 Spare Parts
2.2. Spare Parts IRC5, Control module

Pos

Spare part number


3HAC0053-1 3HAB9764-1 3HAC17970-1 3HAC12934-1 3HAC17971-1 3HAC17973-1 3HAC020892-001 3HAC020890-029 3HAC12817-1 3HAC15639-1 3HNE00554-1 3HNE00065-1 3HNE00025-1 Mains connection and power supply 3HAC020953-002

Description
Multipole con. X8,X9 4p Multip. connector female Dig. 24 VDC I/O Customer I/O Power Supply A D Combi I/O Dig. Relay I/O Heat exchanger unit Customer contact plate DeviceNet M/S Ethernet board Analog I/O Unit Circuit board Circuit board RIO

Note

DSQC 328A DSQC 608 DSQC 327A DSQC 332A

DSQC 603 DSQC 612 APIP-02 ENC-01

Transformer module Backup energy bank Control Power Supply Customer I/O Power supply

1,8kVA DSQC624 DSQC 604 DSQC 608

G3 G2 G4-G5

3HAC020150-001 3HAC12928-1 3HAC12934-1

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2 Spare Parts
2.2. Spare Parts IRC5, Control module

Computer unit

xx0400001236

Spare parts Pos


A3 A3

Spare part number


3HAC020929-001 3HAC020929-002 3HAC12816-1 3HAC020464-001 3HAC020988-001 3HAC020988-002 3HAC020988-003 3HAC 12814-1 3HAC020079-001 3HAC020988-006

Description
Computer A, SSD Computer B, HDD Robot com. card Power supply Mass memory Mass memory Mass memory Main computer board Main computer board Fans

Note
Solid State drive Hard disk drive DSQC 602 DSQC 625 1xHDD 2xHDD 1xSSD DSQC 600 DSQC 623

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3HAC021313-001

2 Spare Parts
2.3. Spare Parts IRC5, Drive module

2.3. Spare Parts IRC5, Drive module


Drive cabinet

xx0400001235

Spare parts Spare part number


3HAC14546-1 3HAC14546-2 3HAC14546-3 3HAC14546-4 3HAC14546-6 3HAC14550-1 3HAC14550-2 3HAC14550-3 3HAC14550-4 3HAC14549-1 3HAC14549-2

Pos
A41.1 A41.1 A41.1 A41.1 A41.1 A41.1.3-5 A41.1.3-5 A41.1.3-5 A41.1.3-5 A41.2 A41.2

Description
Main servo drive unit Main servo drive unit Main servo drive unit Main servo drive unit Main servo drive unit Single servo drive unit Single servo drive unit Single servo drive unit Single servo drive unit Rectifier Rectifier

Info
DSQC 617_3B3A DSQC 617_2E2C2B DSQC 617_3E1C DSQC 617_3G3T DSQC 617_3G3W DSQC 619_C DSQC 619_T DSQC 619_U DSQC 619_W

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21

2 Spare Parts
2.3. Spare Parts IRC5, Drive module

Pos
A41.2 A41.3 A41.3 A41.3

Spare part number


3HAC14549-3 3HAC14551-1 3HAC14551-2 3HAC14551-3 3HAC17281-1

Description
Rectifier Capacitor unit Capacitor unit Capacitor unit DC-bus bar

Info

DC_L6 long busbar with six connector groups DC_S2short busbar with two connector groups DSQC 626 DSQC 627 DSQC 601 8,5kVA 13kVA 1,8kVA 24VDC

3HAC17281-3

DC-bus bar

G1 G1 A42 A43

3HAC020465-001 3HAC020466-001 3HAC020919-001 3HAC13389-2 3HAC020953-003 3HAC020953-004 3HAC020953-006 3HAC6647-1 3HAC020900-001 3HAC12924-3 3HAC020953-001 3HAC7097-1 FlexPendant 3HAC12929-1 3HAC11266-1 3HAC12929-4 3HAC11266-4

Drive system power supply Drive system power supply Axis computer Transformer module Transformer module Transformer module Duty time counter Brake resistor bleeder Fan Fan holder with fans Mains line filter FlexPendant with cable FlexPendant Cable FlexPendant with cable FlexPendant Cable

Contactor Interface board DSQC 611

10m 10m 30m 30m

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3HAC021313-001

3 Circuit Diagram
3.1. Introduction

3 Circuit Diagram
3.1. Introduction
Definitions This chapter specifies the circuit diagram of the IRC5 controller.

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3 Circuit Diagram
3.1. Introduction

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3HAC021313-001

EPLAN

The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.
In no event shall ABB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document.
We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden.

Additional copies of this document may be obtained from ABB at its then current charge.

We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB

Copyright 2004 ABB All right reserved.

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ABB Automation Technologies AB Robotics SE-721 68 Vsters Sweden
Lab/Office:

Latest revision:

Status:

Approved
EPLAN

Title page

Document no.

Prepared by, date:

Approved by, date:

3HAC020538-002 02

= DOKUMENTE Plant: + DKB Location: Sublocation: + Rev. Ind Page 1 Next 2 Total 42

EPLAN

Phone :

: : : 3HAC020538-002_Control :
: 2004-09-28 : : : : : : :
2004-05-05

Customer Robot serial number(s) Drawing number Drawing version

We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB

Manufacture Type Type of installation Control cabinet Mains voltage Supply Control voltage Year of construction

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: : : : : : : jsundin1 2004-09-28 42
Lab/Office:

Project start Project manager Last revision Designed by Designed date Number of pages

Latest revision:

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EPLAN

Title page

Document no.

Prepared by, date:

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3HAC020538-002 02

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Table of contents
Date 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24

DIN_INV_30_1

Plant

Location

Editor

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Page 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

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DOKUMENTEDKB DOKUMENTEDKB DOKUMENTEINV DOKUMENTEINV CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT CM ORT

Page description Title page Title page Table of contents: (1 - 30) Table of contents: (31 - 42) BLOCK DIAGRAM VIEW OF CONTROL MODULE MAINS CONNECTION POWER SUPPLY OPTION: POWER SUPPLY EMERGENCY STOP RUN CHAIN OPERATING MODE SELECTOR, 3 MOD EMERGENCY STOP RUN CHAIN RUN CHAIN OPERATING MODE SELECTOR, 2 MOD RUN CHAIN EXT OPERATING MODE SELECTOR, 2 RUN CHAIN EXT OPERATING MODE SELECTOR, 3 FPU, FLEXPENDANT OPTION: EXTERNAL CONNECTIONSYSTEM SIGNAL VIEW OF COMPUTER UNIT CABLING IN COMPUTER UNIT CABLING IN COMPUTER UNIT COMPUTER UNITCOOLING MAIN COMPUTER ROBOT COMMUNICATION CARD ROBOT COMMUNICATION CARD PROFIBUS DP M/S INTERBUS M/S DEVICENET ADAPTER DEVICENET ADAPTER DUAL RS232 CARD

Page supplementary field Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved

jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1

Latest revision:

Lab/Office:

Status:

Approved
EPLAN

Table of contents: (1 - 30)

Document no.

Prepared by, date:

Approved by, date:

3HAC020538-002 02

= DOKUMENTE Plant: + INV Location: Sublocation: + Rev. Ind Page 3 Next 4 Total 42

Table of contents
Date 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24 2004-09-24

DIN_INV_30_1

Plant

Location

Editor

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Page 31 32 33 34 35 36 37 38 39 40 41 42

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CM CM CM CM CM CM CM CM CM CM CM CM

ORT ORT ORT ORT ORT ORT ORT ORT ORT ORT ORT ORT

Page description ETHERNET CARD DIGITAL PART OF COMBI I/O ANDDIGITAL I/O DIGITAL I/O UNIT COMBI I/O UNIT RELAY I/O UNIT RELAY I/O UNIT RELAY I/O UNIT ANALOGUE I/O UNIT REMOTE I/O UNIT INTERBUS SLAVE PROFIBUS DP SLAVE ENCODER UNIT

Page supplementary field Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved

jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1 jsundin1

Latest revision:

Lab/Office:

Status:

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EPLAN

Table of contents: (31 - 42)

Document no.

Prepared by, date:

Approved by, date:

3HAC020538-002 02

= DOKUMENTE Plant: + INV Location: Sublocation: + Rev. Ind Page 4 Next 5 Total 42

230V

X20

Option Service outlet

Q2

XT16

T3
G3 G2

Ultra cap DC AC DC
A21 G6 G4

AC

Option Devicenet PS

Option Customer PS

Option Customer PS

G5

AC DC

AC DC

F5

A3

F4

Panel board
Computer module

Earth fault prot.


S21

I/Ox

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I/O
unit
Field bus Drive USB Ethernet service

Drive

LAN

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X22

Control panel

FPU

Service outlet

Customer connection

Customer connection

Latest revision:

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EPLAN

BLOCK DIAGRAM

Document no.

Prepared by, date:

Approved by, date:

3HAC020538-002 02

= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 5 Next 6 Total 42

G4 G5 G2 G3 A3

A21 (Panel Board)

X4

X3

G6 if not G5 if G5 G6 in I/O unit.

X18 X20 X7 X18 X11

Q2

X5 X6 X1 X9 X2

S21.3 (emergency pb)

S21.2 (motor on pb)

Epwr EN1 AS1 AS2 GS1 GS2 SS1 SS2 ES1 ES2

S21.1 (mode selector)

X12 X15

X17 X14 X10


A22.X1 I/O2 I/O4 X28 I/O3 I/O1

X22 (opt service outlet)

X20

XS58 XS8 XS13 XS5 XS17 XT6 XT5


=CM+ORT/7 EPLAN CM
Origin

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XS3 XT58 XT8
VIEW OF CONTROL MODULE
Approved 3HAC020538-002_Control

=CM+ORT/5
+ CM Page ORT Crea. for Crea. by

02

2004-09-24

Date

2004-09-28

Edit.

jsundin1

Check.

Modification

Date

Name

Standard

Page 6 42 Pg.

/8.3 / -230V AC1 /9.2 / -230V AC1 /9.5 / -230V AC1 /9.7 / -230V AC1

/8.3 / -230V AC2 /9.2 / -230V AC2 /9.5 / -230V AC2 /9.7 / -230V AC2

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-X16

-181 -308

AWG16 BK AWG16 BK

DRIVE MODULE

CONTROL MODULE

181 181

-Q2

-X20

-X25

-173 -174

AWG16

BK L1 T1 BK L2 T2

-171 -172
L3 T3

AWG16 AWG16

BK BK

230V AC1 230V AC2

AWG16

2 GND

2 GND

-182 -309

AWG16 BK AWG16 BK

182 182

EPLAN
Lab/Office:

-187 -186

AWG16 BK AWG16 BK 5

MAINS CONNECTION
EARTH FAULT BREAKER

OPTION: SERVICE OUTLET

CIRCUIT BREAKER

-F5

-T3

=CM +X22

230V

-F4

AWG16 BK

Status:
-184 -185
AWG16 BK AWG16 BK

115V 7

-183

Document no.

Approved

2 4

1
0V

2
8

3HAC020538-002 02

= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 7 Next 8 Total 42

/10.2 / -24V SYS /10.2 / -0V SYS


/10.2 / -24V COOL /10.2 / -0V COOL

/20.2 / -24V PC /20.2 / -24V PC /20.2 / -0V PC /20.2 / -0V PC

/23.6 / -USB +5V /23.6 / -USB-BP2 /23.6 / -USB-BP2


/23.6 / -USB_GND

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=CM +G2

-X2

-250 -251 -252 -253

BU BU

1 2

BU 3 BU 4

PROCESS POWER SUPPLY

PANEL BOARD COMPUTER UNIT

24V SYS 24V COOL

-X1
1 5

-181 -182

AWG16 BK AWG16 BK

-230V AC1 / /7.1 -230V AC2 / /7.3

AC -INPUT

-X3

-301 -302 -303 -304

BU BU

24V PC

BU 3 BU 4

EPLAN + +
NC Lab/Office: NC

=CM -X1 +G3


1 2 3 4

-X4
1 2 3 4

+
5 5 5

6 6

ULTRA CAP

ULTRA CAP

7 8 +Sense 7 8

POWER SUPPLY
MAIN COMPUTER Status: Document no.

9 10

NC

10 6

-X5

AWG24
AWG28

RD
WH

USB

AWG28 AWG24

GN
3

BK
7 4

Approved

3HAC020538-002 02

= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 8 Next 9 Total 42

/29.1 / -+24V devicenet

/32.1 / -+24V devicenet /32.1 / -0V devicenet

/35.1 / -+24V devicenet /35.1 / -0V devicenet


3

/38.1 / -+24V devicenet /38.1 / -0V devicenet

/39.1 / -+24V devicenet /39.1 / -0V devicenet

/40.2 / -+24V devicenet /40.2 / -0V devicenet


4

/41.1 / -+24V devicenet /41.1 / -0V devicenet

/42.1 / -+24V devicenet /42.1 / -0V devicenet

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DEVICENET POWER SUPPLY =CM -X1 +G6

-X2
AC
+

-308 -309

AWG16 AWG16

BK BK

-230V AC1 / /7.2 -230V AC2 / /7.3


2

DC

/29.1 / -0V devicenet


GND

EPLAN
Lab/Office:

CUSTOMER POWER SUPPLY =CM -X1 +G4

-X2

24V I/O 0V I/O

181 182

-230V AC1 / /7.2 -230V AC2 / /7.3

AC

DC

5 3

Customer Connection

24V I/O
2

OPTION: POWER SUPPLY


Status: Document no.

0V I/O
6 4

CUSTOMER POWER SUPPLY =CM -X1 +G5

-X2

24V I/O 0V I/O

181 182

-230V AC1 / /7.2


7

AC

Approved

DC

-230V AC2 / /7.3

5 3

Customer Connection

24V I/O
2

0V I/O
4 8

3HAC020538-002 02

= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 9 Next 10 Total 42

PANEL BOARD
=CM +A21
BU 1 BU 2 BU 3 BU 4

/8.2 / -24V SYS

-250

-X12

/8.2 / -0V SYS

-251

PROCESS POWER SUPPLY

/8.2 / -24V COOL

-252

/8.2 / -0V COOL

-253

-X1 -X2
3 3 8 0V 4 24V PANEL 4 RunCh_0V RunCh+ 7 6 5

-X10

AWG20 AWG20 AWG20 AWG20

ES1 top ES2 top

-209 -211 -212 -210

-ES FPU 1:A / /17.2 -ES FPU 2:A / /17.2 -ES FPU 2:B / /17.2 -ES FPU 1:B / /17.2

JUNCTION BOARD

EXTERNAL EMERGENCY STOP PB


0V 24V Panel

Run CH1 top Run CH2 top


5 5

-S21.3

EMERGENCY PB -X9
17 18 13 14 11 ES panel 1:A ES panel 1:A ES panel 2:A ES panel 2:A ES panel 2:B ES panel 2:B 12 15 16 ES panel 1:B ES panel 1:B 11 12 21 22

EMERGENCY STOP OUTPUT 1


1 1

ES1OUT:A ES2 OUT:A

EMERGENCY STOP OUTPUT 2


2 2 RunCh_0V 9 9 RunCh+

ES2 OUT:B ES1OUT:B Sep ES2:A Sep ES1:A -ES1


U U

-237 -238 -233 -234 -231 -232 -235 -236

-ES2

Sep ES1:B
A2 A1 A1 10 7 7 8 8 24V PANEL A2 10

Sep ES2:B

EXTERNAL SUPPLY

-X11
1 2 3 4 0V 6 5

ES2 bottom ES1 bottom 0V 24V Panel

AWG24

OG BU
WHBU WHBN

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-24V_Sig.ref. / /24.5 -RS485+ / /24.5 -RS485- / /24.5

ROBOT COMM. CARD -0V_Sig.ref. / /24.5


7 8 SOFT_ESO

ES1:int
6

Latest revision:

Lab/Office:

+ORT/12.6 / -RunCh+ +ORT/12.5 / -RunCh_0V +ORT/12.6 / -RCH2 +ORT/12.7 / -RCH1


ES1 ES2 SOFT_ESI

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ES2:int
6

EMERGENCY STOP RELAY SIGNALS

Status:

Approved
EPLAN

EMERGENCY STOP

Document no.

Prepared by, date:

Approved by, date:

3HAC020538-002 02

= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 10 Next 11 Total 42

PANEL BOARD
=CM +A21

-X3
General in1 General in2 2 General in3 General in4 4 General in5 General in6 6 General in7 General in8 8 0V +24V 10 9 10 General out1 General out2 AWG20 AWG20 AWG20 6 AWG20 AWG20 3 AWG20 2 AUTO2 MAN2 4 MAN FS2 AUTO1 MAN1 2 General out3 General out4 4 General out5 General out6 6 General out7 General out8 8 0V 9 7 5 7 3 8 8 9 7 7 9 5 4 AWG20 3 AWG20 3 2 AWG20 1 AWG20 AWG20 1

-X10
-205 -206 -207 -208 -213 -24V FPU_POWER / /17.2 -0V / /17.2 -EN1_1 / /17.2 -EN1_2 / /17.2 -FPU START / /17.2

JUNCTION BOARD

-X6
EN2_1A EN2_1B EN2_2A EN2_2B

OPTION EXTERNAL ENABLE DEVICE -S21.1.X1


3 2 1 4 7 6 5 8

-X4
1

EXT.MAN2

EXT.AUTO2

EXT MAN FS2

EXT.AUTO1 EXT.COMMON2

EXT.MAN1

EXT MAN FS1

=CM +A23

-ES2
>1

MODE SELECTOR -S21.1 6 1210


5

2 4 8 1
24V panel 0V

182224 17

141620 13

-ES1
WHOG AWG20 1 5 AWG20 OG 1 2 4 5 3 6 7 8 9 AWG20 19 10 BU
WHBU

-SUP_ST2

-X2

AWG26

-X20

-SUP_ST1
WHGN GN
WHBN

-220 -224

-GS2 0V

RS485+ RS48524V DC

MOTOR ON PB
-S21.2
AWG20 AWG20 MOTON 24V PANEL MONLMP 14 13

-GS1
BN

-AS2

-229 -228 -230

-AS1

X2

X1

-ENABLE1

OPTION: DOOR FAN 52


=CM +E3
-

+ORT/13.3 / -SPEED +ORT/12.5 / -EN1 +ORT/12.5 / -EN2 +ORT/12.5 / -MAN1 +ORT/12.4 / -MAN2

1~
+

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24V PANEL

EXT COMPUTER FAN -X1


2 1

-X15
1 3

OP_COM OP_MAN

=CM +E2

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2 2 1

TACHO
2 4 3

-362

AWG20 BU 3

BN
2

OP_AUTO OP_MAN_FS

FAN 0V
1

-363

AWG20 BU;BU

-360

AWG20 1

BK
3

Latest revision:

Lab/Office:

Status:

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EPLAN Document no.

Prepared by, date:

Approved by, date:

RUN CHAIN OPERATING MODE SELECTOR, 3 MODES

3HAC020538-002 02

= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 11 Next 12 Total 42

24V COOL

-X18 -364

AWG20 BU;BU

-361

AWG20

-X18

RD

-X1

M
-

EXT.COMMON1

OPTION: STATUS LED ON FRONT

-227 -226 -225 -223 -222 -221


MAN FS1

-245 -244 -243 -246 -241 -240 -239 -242

-X9

EMERGENCY STOP
Status: Document no.

+ORT/13.3 / -ENABLE2_1 +ORT/13.3 / -ENABLE2_2 +ORT/13.3 / -ENABLE2_3 +ORT/13.3 / -ENABLE2_4

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AUTO STOP

GENERAL STOP

SUPERIOR STOP
GS1GS2+ GS2-

SS1+

AS1+

AS2GS1+

SS1SS2+

AS1AS2+

SS23 5

11

12

-X6

-X5

PANEL BOARD =CM +A21

4 1

2 4

8 10

3 5

7 1 6

24V PANEL 0V

24V PANEL 24V PANEL 0V 0V

SS2
SS2 SOFT SS

SS1
SS1

AS2

AS1

GS2
GS2 SOFT GS

GS1
GS1

AS2

AS1 4

EPLAN
Lab/Office: CH2

SOFT AS

-MAN2 / +ORT/11.4 -MAN1 / +ORT/11.4

-EN2 / +ORT/11.4 -EN1 / +ORT/11.4 -RunCh_0V / +ORT/10.5

&
-RunCh+ / +ORT/10.5
6

&

+ORT/13.4 / -RCH2
CH1

-RCH2 / +ORT/10.6

+ORT/13.4 / -RCH1

-RCH1 / +ORT/10.6
7

Approved

3HAC020538-002 02

= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 12 Next 13 Total 42

PANEL BOARD

=CM +A21 +ORT/12.7 / -RCH1 +ORT/12.6 / -RCH2

CONTROL MODULE

-X7
0V 2 4 3 5 6 7 8 9 10 1

RUN CH1 RUN CH1Ret

24V PANEL

+ORT/11.4 / -SPEED +ORT/12.5 / -ENABLE2_1 +ORT/12.5 / -ENABLE2_2 +ORT/12.5 / -ENABLE2_3 +ORT/12.5 / -ENABLE2_4 -X8
0V 2 24V PANEL 3 5 6 7 8 9 10 4 1

RUN CH2Ret RUN CH2 SPEED 0V ENABLE2_1 ENABLE2_1Ret AC_ON1 0V

Drive module1 A43.X1

RUN CH1 RUN CH1Ret

if not used

Drive module2 A43.X1 if not used

RUN CH2Ret RUN CH2 SPEED 0V ENABLE2_2 ENABLE2_2Ret AC_ON1 0V

-X14
0V 2 4 24V PANEL 3 5 6 7 8 9 10 1

RUN CH1 RUN CH1Ret


Drive module3 A43.X1 if not used

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RUN CH2Ret RUN CH2 SPEED 0V ENABLE2_3 ENABLE2_3Ret AC_ON1 0V

if not used

-X17
0V 2 4 24V PANEL 3 5 6 7 8 9 10 1

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RUN CH1 RUN CH1Ret
Drive module4 A43.X1 if not used RUN CH2Ret RUN CH2 SPEED 0V ENABLE2_4 ENABLE2_4Ret AC_ON1 0V if not used
Lab/Office:

Latest revision:

Status:

Approved
EPLAN

RUN CHAIN

Document no.

Prepared by, date:

Approved by, date:

3HAC020538-002 02

= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 13 Next 14 Total 42

PANEL BOARD =CM +A21

-X9
-222
AWG20 BU AWG20 BU AWG20 BU AWG20 BU AUTO1 MAN1 AUTO2 MAN2 OG OG OG OG

-241 -240 -245 -244

EXT.AUTO1 EXT.MAN1

-S21.1.X1
7

-221
2

-226
7

EXT.AUTO2 3 EXT.MAN2 2

-225
6

OPTION

MODE SELECTOR
-S21.1
1 2 .5 6 14 .5 10 .5 3 5 9 7 11 13 15

-224
AWG20 BU AWG20 BU 24V panel 0V 5

-246 -242

OG OG

EXT.COMMON2 4 EXT.COMMON1 8

-220
1

MOTOR ON PB
-S21.2 -229
AWG20 BU AWG20 BU X2 AWG20 BU 24V PANEL MONLMP MOTON 14 13 10

-230
19

X1

-228
9

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EPLAN Document no.

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Approved by, date:

RUN CHAIN OPERATING MODE SELECTOR, 2 MODES

3HAC020538-002 02

= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 14 Next 15 Total 42

CONTROL MODULE

EXT. CONTROL PANEL -Ext.A21.X9


AWG20 AWG20 AWG20 AWG20 AUTO1 MAN1 EXT.AUTO2 EXT.MAN2 3 2 AUTO2 EXT.MAN1 MAN2 EXT.AUTO1

PANEL BOARD =CM +A21


3 2 7 6 7 6

-X9
-222 -221 -226 -225 -241 -240 -245 -244

-S21.1.X1

MODE SELECTOR
-S21.1
1 2 AWG20 AWG20 24V panel 0V .6 6 14 EXT.COMMON2 EXT.COMMON1 4 .6 10 .6 3 5 7 9 11 13 15

OPTION

5 1

-224 -220

-246 -242

MOTOR ON PB
-S21.2 -229
AWG20 AWG20 AWG20 24V PANEL MONLMP MOTON 14 10 19 13

10

19 9

-230 -228
X2

X1

-S21.3
ES panel 1:A ES panel 1:A ES panel 2:A ES panel 2:A ES panel 2:B ES panel 2:B ES panel 1:B ES panel 1:B 17 18 13 14 11 12 15 16

EMERGENCY PB
21 11 22 12

17

18

13

14

11

12

15

-237 -238 -233 -234 -231 -232 -235 -236

16

JUNCTION BOARD
=CM +A22

-X10

-X3
1 2 3 4 5 6 7

BN/BK BN/RD BN/OG BN/YE

24V TPU 0V EN1_1 EN1_2

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BN/GN

TPU_START

8 9

ROBOT COMMUNICATION CARD


AWG24 WHOG OG WHGN GN 4 2 3

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-X2
1

=CM +A32

-A8

TD+ TDRD+ RD-

Latest revision:

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Status:

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EPLAN Document no.

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Approved by, date:

RUN CHAIN EXT OPERATING MODE SELECTOR, 2 MODES

3HAC020538-002 02

= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 15 Next 16 Total 42

CONTROL MODULE

EXT. CONTROL PANEL -Ext.A21..X9


AWG20 AWG20 EXT MAN FS2 EXT.AUTO1 EXT.MAN1 EXT MAN FS1 6 5 1 7 MAN1 EXT.MAN2 MAN FS1 EXT.AUTO2

PANEL BOARD =CM +A21


8 7 6 4 AWG20 AWG20 AUTO2 3 2 MAN2 AUTO1 AWG20 AWG20 MAN FS2 3 2

-X9
-227 -226 -225

-S21.1.X1

-223 -222 -221

-245 -244 -243 -241 -240 -239

MODE SELECTOR
-S21.1 6 1210 5
AWG20 AWG20 24V panel 0V 5 .7

2 4 8 1
.7

182224 17
.7

141620 13
EXT.COMMON1 EXT.COMMON2 8 4

OPTION

5 1

-224 -220

-242 -246

MOTOR ON PB
-S21.2 -229
AWG20 AWG20 AWG20 24V PANEL MONLMP MOTON 10 X2 X1 19 14 13

10

19 9

-230 -228

-S21.3
ES panel 1:A ES panel 1:A ES panel 2:A ES panel 2:A ES panel 2:B ES panel 2:B ES panel 1:B ES panel 1:B 17 18 13 14 11 12 15 16

EMERGENCY PB
21 11 22 12

17

18

13

14

11

12

15

-237 -238 -233 -234 -231 -232 -235 -236

16

JUNCTION BOARD
=CM +A22

-X10

-X3
1 2 3 4 5 6 7

BN/BK BN/RD BN/OG BN/YE 24V TPU 0V EN1_1 EN1_2

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BN/GN

TPU_START

8 9

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AWG24 WHOG OG WHGN GN 6 2 3

ROBOT COMMUNICATION CARD -X2


1

=CM +A32

-A8

TD+ TDRD+ RD-

Latest revision:

Lab/Office:

Status:

Approved
EPLAN Document no.

Prepared by, date:

Approved by, date:

RUN CHAIN EXT OPERATING MODE SELECTOR, 3 MODES

3HAC020538-002 02

= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 16 Next 17 Total 42

OPTION: FPU-PLUG X22.XP1


3 5

JUNCTION BOARD
6 4 =CM +A22

FLEXPENDANT
=CM +FPU -209
AWG20 BU 5 3 5 6 4 EN-DEVICE 1 AWG20 BU 7 AWG20 8 AWG20 BU 6

EMERGENCY-STOP

/10.7 / -ES FPU 1:A


-211 -212 -210

-X3

-X1

-K1

PANEL BOARD

/10.7 / -ES FPU 2:A

/10.7 / -ES FPU 2:B

/10.7 / -ES FPU 1:B

-K2

/11.6 / -24V FPU_POWER


AWG20 BU 1 12 2 8 AWG20 BU 2

-205 -206

PANEL BOARD
-207
AWG20 3 7 17 AWG20 4

/11.6 / -0V

/11.6 / -EN1_1 -208

/11.6 / -EN1_2

/11.6 / -FPU START


AWG20 BU 9 AWG24 WHOG 1 OG 2 WHGN 3 GN 6

-213

11

/24.6 / -TD+

-X2
13 14

ROBOT COMM. CARD

/24.6 / -TD-

/24.6 / -RD+

ETH_FPU
15 16

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Lab/Office:

/24.6 / -RD-

Latest revision:

Status:

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EPLAN

FPU, FLEXPENDANT

Document no.

Prepared by, date:

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= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 17 Next 18 Total 42

PANEL BOARD PANEL BOARD


=CM +A21
AWG20 BU 12 AWG20 BU B1 11

=CM +A21 -260


OG A1 OG AWG20 BU B2 9 AWG20 BU A2 7 AWG20 BU A3 C5 AWG20 BU

ES1 bottom
AWG20 BU AWG20 BU

-X1 24V PANEL AS1+ AS1AWG20 BU

-XS/XP3
-272 -273 -274 -275
AWG20 BU

-X5

-XS/XP3
C1 C2

AWG20 BU

ES2 bottom
-262 -263 0V -264 GS1+
10

-X2
-261

24V PANEL

AWG20 BU C3 C4 AWG20 BU

0V

24V PANEL
-276 -277
8

Run CH1 top


GS1-265
AWG20 BU B3 OG B4 6 OG A4 5 AWG20 BU A5 3 AWG20 BU B5 1 OG OG OG B6 AWG20 BU

AWG20 BU C6 AWG20 BU C7 C8 AWG20 BU

Run CH2 top

0V -266

ES2 top
-267

24V PANEL AS2+ AS20V

-278 -279 -280 -281

AWG20 BU D1 AWG20 BU D2 AWG20 BU D3 AWG20 BU D4

AWG20 BU

ES1 top
-268 -269 -270 -271
OG A6 4 OG A7 OG A8

Sep ES1:A

AWG20 BU

Sep ES2:A

Sep ES2:B
GS2+ GS22

AWG20 BU D5

10

Sep ES1:B
-284 -285 -286
OG B7 OG B8

-282 -283

AWG20 BU D6 AWG20 BU D7 D8 AWG20 BU

10

ES1 OUT A

ES1 OUT B

ES2 OUT A
-287

ES2 OUT B

0V

-X6
1

-289

AWG20 BU A10

AWG20 BU

SS12

-291

AWG20 BU B10

SS23

-293

AWG20 BU C10

SS1+
4

-290

AWG20 BU B9

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SS2+
5

-292

AWG20 BU C9

24V PANEL
6 7 8 9 10

-288

AWG20 BU A9

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OPTION: EXTERNAL CONNECTION SYSTEM SIGNALS

3HAC020538-002 02

= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 18 Next 19 Total 42

A3 Computer unit

X1
PWR (green)

HDD (yellow) A32 (RCC)

Slot 1 Slot 2

Slot 3

Slot 4

Slot 5

USB1,2

USB3,4

LAN

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SERIAL PORT A A33 Profibus DP M/S A37 Interbus M/S (optical fiber) A38 Interbus M/S (copper wire) A35 Devicenet
EPLAN CM
Origin

=CM+ORT/18 VIEW OF COMPUTER UNIT


Approved 3HAC020538-002_Control

=CM+ORT/20
+ CM Page ORT Crea. for Crea. by

02

2004-09-24

Date

2004-09-24

Edit.

jsundin1

Check.

Modification

Date

Name

Standard

Page 19 42 Pg.

COMPUTER UNIT
=CM +A3 COMPUTER POWER SUPPLY =CM +G31 -301
BU P1 1 V+ BU 4 BU OR OR BK 3 RD BK RD BK MOTHER BOARD POWER V+3.3V GND +5V GND +5V GND 7 GY VT YE OR BU PWR_OK 8 +5VSB 9 +12V +3.3V -12V GND BK GN 3 BK BK BK RD RD GND GND GND 17 +5V +5V 19 20 18 15 16 PS_ON 13 14 11 12 10 5 6 3 4 +3.3V 2 BU

MAIN COMPUTER -X1


=CM +A31

/8.3 / -24V PC
-302 -303 -304 -P1

-X1

PROCESS POWER SUPPLY

/8.3 / -24V PC

/8.3 / -0V PC

-J4H1
1 2

/8.3 / -0V PC

-PSU-X1 -PSU-X2
-P1
1 1

-PSU-X2
2

-P1

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-IDEpwr
-IDEpwr_GND / +ORT/21.2 -IDEpwr_+5V / +ORT/21.2
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CABLING IN COMPUTER UNIT

Document no.

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COMPUTER UNIT MAIN COMPUTER


=CM +A31

=CM +A3

SOLID STATE DRIVE


=CM +D32

-X2
-J6H1
ATA/IDE

40

-X1
1 2 3 4

+ORT/20.7 / -IDEpwr_GND +ORT/20.7 / -IDEpwr_+5V

GND +5V

OPTION: HARD DISK DRIVE


=CM +D31

-X2 -X1
1 1 2 3 4

40 -J6H1

ATA/IDE

GND +5V

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REMARK: P1 & J6H1 CONNECTS TO EITHER D32 OR D31 DEPENDING OF CHOSED OPTION.
Lab/Office:

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EPLAN

CABLING IN COMPUTER UNIT

Document no.

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COMPUTER UNIT

=CM +A3

COMPUTER POWER SUPPLY

=CM +G31

P1

BK YE +12V

GND

CHASSIS BLOWER -E22

MAIN COMPUTER
BK GND +12V

M
AWG 24

=CM +A31 -J9H1


1 2
WH

-C2
1 2

BK RD

YE

FAN2_TACH

CHASSIS BLOWER -E23 -J9H2


1 2 3 AWG 24

M
+
BK YE GND +12V

-C1
1 2

BK RD

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WH

FAN1_TACH

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COMPUTER UNIT COOLING

3HAC020538-002 02

= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 22 Next 23 Total 42

COMPUTER UNIT
CONTROL MODULE

=CM +A3

MAIN COMPUTER
=CM +A31
PWR LED (GREEN)

-J9H3
A K SERIAL PORT A

RX1 TRANSMIT OUT HDD LED (YELLOW) A 4 5 RTS 7 8 9 9 8 7 6 3 1 K RECEIVE IN 3 DTR 0V 5 6 4 3 2 2 1 4

OPTION: 232/485 SERIE CONVERTER =CM +A39 -X1 -X2


-A1
2

TX+

TX-

0V

OPT. EXTERNAL PWR

RX+

-LAN1
TX+ TXRX+ 3 RX6 1 2

-USB1
2 3 1 4

=CM +X24
AWG28 AWG28 AWG24 AWG24 WH GN RD BK USB-BP1 USB-BP1 +5V GND 2 3 1 4

-USB2
2 3 1 4

AWG28 AWG28 AWG24 AWG24

WH GN RD BK

-USB-BP2 / /8.7 -USB-BP2 / /8.7 -USB +5V / /8.6 -USB_GND / /8.7

PROCESS POWER SUPPLY

-USB3
1 2 3 4

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-USB4
1 2 3 4 Lab/Office:

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MAIN COMPUTER

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ROBOT COMMUNICATION CARD

=CM +A32

-X8
AWG24 Blue 1 2 3 BU
WHBU

OG

RS 485
4 5 6 7 8
WHBN

-24V_Sig.ref. / /10.7 -RS485+ / /10.7 -RS485- / /10.7

PANEL BOARD

-X1

-0V_Sig.ref. / /10.7

PCI BUS
AWG24

-A8
Green WHOG OG 3

-TD+ / /17.2 -TD- / /17.2

FLEXPENDANT

ETH_FPU
6 4 5 1 2 7 8

WHGN GN

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-RD+ / /17.2 -RD- / /17.2
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ROBOT COMMUNICATION CARD

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CONTROL MODULE

ROBOT COMMUNICATION CARD


=CM +A32 -A9
Red 1 2 3

TX+ TXRX+ RX-

ETH_DRIVE
6 4 5 7 8

DRIVE MODULE AXIS COMPUTER

-A7
Yellow 1 2

=CM +X23
1 2 3

TX+ TXRX+

AWG26 AWG26 AWG26

BU WHBU OG

SERVICE PORT
6

ETH_SERVICE
3 4 5 6 7 8

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RXAWG26 WHOG
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PROFIBUS DP M/S
Customer Connection

=CM +A33

-X1 -X2
1 3 4 5 6 8

SLAVE

PCI BUS

SHIELD RXD/TXD-P CONTROL-P GND +5VDC RXD/TXD-N

-X3
1 3 4 5 6 8

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SHIELD RXD/TXD-P CONTROL-P GND +5VDC RXD/TXD-N
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OPTION & HARNESS TO CUSTOMER I/O

MASTER

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PROFIBUS DP M/S

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INTERBUS M/S (OPTICAL FIBRE)


A38.1 =CM +A38

INTERBUS M/S (COPPER WIRE) -X4


24V 0V
0V 24V+

=CM +A37

A37.1

1)

-Z1
24V+

-X2
24V 0V
0V 1 4 REMOTE IN

1)

-Z1 -X5

PCI BUS
LW/BK
REMOTE IN BK (IN)

-FO1

PCI BUS
LW/OG

5 3

DO DON DI DIN GNDISI

GY (OUT)

-FO2 LW/BK LW/OG


GY (OUT) REMOTE OUT BK (IN)

REMOTE OUT

-X1
1 6 2 7 3 5 9

A37.2 -FO3 LW/BK LW/OG


GY (OUT) REMOTE BK (IN)

DO DON DI DIN GRND VCCISO RBST

OPTION & HARNESS TO CUSTOMER I/O

A38.2
REMOTE

1 6 2 7 3 4 5 8

-X1
1 2 4 5 6

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TXD RXD GND RTS CTS

DO DON DI DIN GNDIM GRND VCCIM VCC

RS232

-X3
1 2 4 5 6

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TXD RXD GND RTS CTS
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1) IT IS IMPORTANT THAT 24 DC EXT SUPPLY ALWAYS IS AVAILABLE OTHERWISE THE INTERBUS CAN NOT WORK IF THE CONTROLLER IS TURNED OFF. Status:

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INTERBUS M/S

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OPTION & HARNESS TO CUSTOMER I/O -X2

DEVICE NET ADAPTER

=CM +A35

CONTROL MODULE

-XS17
-J1 BK
3 1 1

P1 BU
2 2 5

-A35.X1

SC
3 3 1

WH
4 4 4

OPTION

PCI BUS
5 5

RD
2

-V- / /29.2
-CAN_L / /29.2

-DRAIN / /29.2 -CAN_H / /29.2 -V+ / /29.2

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EPLAN

DEVICENET ADAPTER

Document no.

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-I/O1
1 2 3 4 5

/28.5 / -V/28.5 / -CAN_L /28.5 / -CAN_H /28.5 / -V+ /28.5 / -DRAIN Digital I/O unit

-I/O2
1 2 3 4 5

BK BU WH RD SC

-V- / /32.1 -CAN_L / /32.1 -CAN_H / /32.1 -V+ / /32.1 -DRAIN / /32.1

BK BU WH RD SC

-V- / /35.1 -CAN_L / /35.1 -CAN_H / /35.1 -V+ / /35.1 -DRAIN / /35.1 Relay I/O unit

-I/O3
1 2 3 4 5

BK BU WH RD SC

-V- / /38.1 -CAN_L / /38.1 -CAN_H / /38.1 -V+ / /38.1 -DRAIN / /38.1

Analogue I/O unit

-I/O4
1 2 3 4 5

OPTION: HARNESS TO CUSTOMER I/O Remote I/O unit

BK BU WH RD SC

-V- / /39.1 -CAN_L / /39.1 -CAN_H / /39.1 -V+ / /39.1 -DRAIN / /39.1

BK BU WH RD SC

-V- / /40.2 -CAN_L / /40.2 -CAN_H / /40.2 -V+ / /40.2 -DRAIN / /40.2

Interbus slave

/9.2 / -0V devicenet


1 2 120 OHM 3 4 5

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-A35.X2

BK BU WH RD SC

-V- / /41.1 -CAN_L / /41.1 -CAN_H / /41.1 -V+ / /41.1 -DRAIN / /41.1

Profibus DP slave

Encoder unit

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BK BU WH RD SC

/9.2 / -+24V devicenet

-V- / /42.1 -CAN_L / /42.1 -CAN_H / /42.1 -V+ / /42.1 -DRAIN / /42.1

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Document no.

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DUAL RS232 CARD


=CM +A34

-X1
1 2 3 4 5 6 7 8

MC CONSOLE RS232

CONSOLE_RXD CONSOLE_TXD CONSOLE_DTR 0V CONSOLE_DSR CONSOLE_RTS-N CONSOLE_CTS-N

X5
9

-X2
1

PCI BUS
2 3 4 5 6 7 8 9

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COM1 RS232

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COM1_RXD COM1_TXD COM1_DTR 0V COM1_DSR COM1_RTS-N COM1_CTS-N

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DUAL RS232 CARD

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ETHERNET CARD

=CM +A36

-A1
1 2 3 4 5

TX+ TXRX+
DRIVE MODULE 2 (OPTION)

RX-

X1
6 7 8

-A2
1

PCI BUS
2 3 4 5 6 7 8

TX+ TXRX+
DRIVE MODULE 3 (OPTION)

RX-

-A3
1 2 3 4 5 6 7 8

TX+ TXRX+
DRIVE MODULE 4 (OPTION)

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ETHERNET CARD

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TO NEXT I/O UNIT

2)
120 ohm 2 1

3)

/9.3 / -+24V devicenet /9.3 / -0V devicenet

DIGITAL PART OF COMBI I/O AND DIGITAL I/O UNIT I/Ox


K 1 A 2 3 K 5 2 4 5 9 3 6 10 1 8 2 47nF 7 6 4 A

XTXX.X3 -X3

-X5
1

/29.5 / -V/29.5 / -CAN_L /29.5 / -CAN_H /29.5 / -V+

INPUT CH.1 2 3 4 5 6 7 8 0V

/29.5 / -DRAIN
0V

OR PREVIOUS I/O UNIT


7 8 9 10 11 12 2 A 4 K 47nF 1 2 6 7 8 9 10 5 3 K A

1)

0V NA0 NA1 NA2 NA3 NA4 NA5

XTXX.X4 -X4
1

1) JUMPERS PLACED ACCORDING TO THE ACTUAL NODE ADDRESS.

INPUT CH.9 10 11 12 13 14 15 16 0V

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2) RESISTANS 120 OHM SHALL ALWAYS BE CONNECTED IN THE FIRST AND THE LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

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3) CONNECTED IN THE LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

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DIGITAL I/O UNIT

I/Ox OUTPUT CH 1-8 XTXX.X1


A

<1
1 1 2 3 4 2 5 6 7 8 9 10 A

-X1

47nF K

0V

OUTPUT CH.1 2 3 4 5 6 7 8 0V 24V DC

OUTPUT CH 9-16 XTXX.X2


A

<1
1 1 2 3 4 2 5 6 7 8 9 10 A

-X2

47nF K 2 1

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OUTPUT CH.9 10 11 12 13 14 15 16 0V 24V DC
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COMBI I/O UNIT

I/Ox OUTPUT CH 1-8 XTXX.X1


A

<1
1 1 2 3 4 2 5 6 7 8 9 10 A

-X1

47nF K 2 1

0V

OUTPUT CH.1 2 3 4 5 6 7 8 0V 24V DC

OUTPUT CH 9-16 XTXX.X2


A

<1
1 1 2 3 4 2 5 6 7 8 9 10 A

-X2

47nF K 2 1

OUTPUT CH.9 10 11 12 13 14 15 16 0V 24V DC

-X6
1 2

CPU
K A A K

INPUT CH.1 INPUT CH.2

0V
3

DAC

OUTPUT CH.1
5 REF 4

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0VA OUTPUT CH.2


6

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+15V 0VA -15V Lab/Office:

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TO NEXT I/O UNIT

2)
120 ohm 2 1

3)

RELAY I/O UNIT I/Ox XTXX.X3


K 1 A 2 3 K 5 2 4 5 9 3 6 1 8 2 47nF 7 6 4 A

/9.3 / -+24V devicenet /9.3 / -0V devicenet

-X3

-X5
1

/29.5 / -V/29.5 / -CAN_L /29.5 / -CAN_H /29.5 / -V+

INPUT CH.1 2 3 4 5 6 7 8 0V

/29.5 / -DRAIN
0V

OR PREVIOUS I/O UNIT


7 8 9 10 11 12 1 2 A 4 K 47nF 1 2 6 7 8 9 5 3 K A

1)

0V NA0 NA1 NA2 NA3 NA4 NA5

XTXX.X4 -X4 INPUT CH.9 10 11 12 13 14 15 16 0V

1) JUMPERS PLACED ACCORDING TO THE ACTUAL NODE ADDRESS.

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2) RESISTANS 120 OHM SHALL ALWAYS BE CONNECTED IN THE FIRST AND THE LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

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RELAY I/O UNIT

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RELAY I/O UNIT

XTXX.X1 -X1
1

OUT CH.1A

OUT CH.1B 2

OUT CH.2A 3

OUT CH.2B 4

OUT CH.3A 5

OUT CH.3B 6

OUT CH.4A 7

OUT CH.4B 8

OUT CH.5A 9

OUT CH.5B 10

OUT CH.6A 11

OUT CH.6B 12

OUT CH.7A 13

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OUT CH.7B 14

OUT CH.8A 15

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RELAY I/O UNIT

XTXX.X2 -X2
1

OUT CH.9A

OUT CH.9B 2

OUT CH.10A 3

OUT CH.10B 4

OUT CH.11A 5

OUT CH.11B 6

OUT CH.12A 7

OUT CH.12B 8

OUT CH.13A 9

OUT CH.13B 10

OUT CH.14A 11

OUT CH.14B 12

OUT CH.15A 13

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OUT CH.15B 14

OUT CH.16A 15

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OUT CH.16B 16 Lab/Office:

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TO NEXT I/O UNIT

2)
120 ohm 2 1

ANALOGUE I/O UNIT I/Ox -X7


1 2 3 4 19 0V 20 21 22

3)

/9.3 / -+24V devicenet /9.3 / -0V devicenet ADC

MUX

-X5
1 2 4 5 3 6 7 8 9 10 11 12 5 6 7 8 9 0V 10 11 12 13 14 15 4 3 2 1 REF

ANOUT_1 ANOUT_2 ANOUT_3 ANOUT_4 0V 0V 0V 0V

/29.5 / -V/29.5 / -CAN_L /29.5 / -CAN_H /29.5 / -V+

/29.5 / -DRAIN
DAC

OR PREVIOUS I/O UNIT -X8


1)

0V NA0 NA1 NA2 NA3 NA4 NA5

ANIN_1 ANIN_2 ANIN_3 ANIN_4


24V

1) JUMPERS PLACED ACCORDING TO THE ACTUAL NODE ADDRESS.

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2) RESISTANS 120 OHM SHALL ALWAYS BE CONNECTED IN THE FIRST AND THE LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

0V 0V 0V 0V

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3) CONNECTED IN THE LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

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TO NEXT I/O UNIT

2)
120 ohm 2 1

3)

/9.3 / -+24V devicenet /9.4 / -0V devicenet

I/Ox

REMOTE I/O UNIT

-X5
1 2 4 5 3 6 7 8 9 10 11 12 2 3 1 1

NAC

/29.5 / -V/29.5 / -CAN_L /29.5 / -CAN_H /29.5 / -V+ -X8

LINE 1 (BLUE)

REMOTE I/O IN

/29.5 / -DRAIN
1
2

LINE 2 (CLEAR)
-X9

OR PREVIOUS I/O UNIT


1)

0V NA0 NA1 NA2 NA3 NA4 NA5

(BLUE) (CLEAR)

REMOTE I/O OUT

-X8
3 1 1 2 2

1) JUMPERS PLACED ACCORDING TO THE ACTUAL NODE ADDRESS.

2) RESISTANS 120 OHM SHALL ALWAYS BE CONNECTED IN THE FIRST AND THE LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

-X9
4

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2)
120 ohm 2 1

3)

/9.4 / -+24V devicenet /9.4 / -0V devicenet

INTERBUS SLAVE I/Ox

-X5
1 TPDO2 TPDI2 GND 3 5 3 6 7 8 9 10 11 12 9 7 6 +5VDC TPDO2-N TPDI2-N RBST 2 4 5 2 1

/29.5 / -V/29.5 / -CAN_L /29.5 / -CAN_H /29.5 / -V+ -X21

IB-S OUT

/29.5 / -DRAIN

OR PREVIOUS I/O UNIT


1)

0V NA0 NA1 NA2 NA3 NA4 NA5

-X20
1 2 3 6 7

TPDO1 TPDI1 GND TPDO1-N TPDI1-N

IB-S IN

GND

-X3
1 3 5

4) 24V DC EXT. SUPPLY


+24VDC

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1) JUMPERS PLACED ACCORDING TO THE ACTUAL NODE ADDRESS.

2) RESISTANS 120 OHM SHALL ALWAYS BE CONNECTED IN THE FIRST AND THE LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

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3) CONNECTED IN THE LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

4) IT IS IMPORTANT THAT 24V DC EXT SUPPLY ALWAYS IS AVAILABLE. OTHERWISE THE INTERBUS CAN NOT WORK IF THE CONTROLLER IS TURNED OFF.

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INTERBUS SLAVE

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TO NEXT I/O UNIT

2)
120 ohm 2 1

3)

PROFIBUS DP SLAVE I/Ox


Customer Connection

/9.4 / -+24V devicenet /9.4 / -0V devicenet

-X5
1 SHIELD RXD/TXD-P 5 4 3 6 7 8 9 10 11 12 8 6 5 GND +5VDC RXD/TXD-N 3 CONTROL-P 2 4 1

/29.5 / -V/29.5 / -CAN_L /29.5 / -CAN_H /29.5 / -V+ -X20

/29.5 / -DRAIN

OR PREVIOUS I/O UNIT


1)

0V NA0 NA1 NA2 NA3 NA4 NA5

0V DC

-X3
1 3 5

External supply
GND +24VDC

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1) JUMPERS PLACED ACCORDING TO THE ACTUAL NODE ADDRESS.

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2) RESISTANS 120 OHM SHALL ALWAYS BE CONNECTED IN THE FIRST AND THE LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

3) CONNECTED IN THE LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

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2)
120 ohm 2 1

3)

ENCODER UNIT I/Ox


Encoder Connection

/9.4 / -+24V devicenet /9.4 / -0V devicenet

-X20
24 VDC 0V 2 2 ENC +24V 3 5 ENC 0V 4 3 ENC_A 5 A ENC_B 6 +24V 10 11 12 A 9 K 2 8 DIGIN 1 7 0V 8 K 9 6 7 2 1 4

-X5
1

/29.5 / -V/29.5 / -CAN_L /29.5 / -CAN_H /29.5 / -V+

/29.5 / -DRAIN

Encoder

OR PREVIOUS I/O UNIT


1)

0V NA0 NA1 NA2 NA3 NA4 NA5

Synch switch

2 A K

1) JUMPERS PLACED ACCORDING TO THE ACTUAL NODE ADDRESS.

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2) RESISTANS 120 OHM SHALL ALWAYS BE CONNECTED IN THE FIRST AND THE LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

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EPLAN

The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.
In no event shall ABB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document.
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Additional copies of this document may be obtained from ABB at its then current charge.

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Copyright 2004 ABB All right reserved.

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ABB Automation Technologies AB Robotics SE-721 68 Vsters Sweden
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Title page

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EPLAN

Phone :

: : : 3HAC020538-002_Drive :
: 2004-09-28 : : : : : : :
2004-02-04

Customer Robot serial number(s) Drawing number Drawing version

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Manufacture Type Type of installation Control cabinet Mains voltage Supply Control voltage Year of construction

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: : : : : : : jsundin1 2004-09-28 18
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Project start Project manager Last revision Designed by Designed date Number of pages

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Table of contents
Date 2004-09-13 2004-09-13 2004-09-23 2004-09-22 2004-09-22 2004-09-22 2004-09-23 2004-09-22 2004-09-22 2004-09-22 2004-09-22 2004-09-22 2004-09-22 2004-09-22 2004-09-22 2004-09-22 2004-09-22 2004-09-22

DIN_INV_30_1

Plant

Location

Editor

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Page 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

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DOKUMENTEDKB DOKUMENTEDKB DOKUMENTEINV DM ORT DM ORT DM ORT DM ORT DM ORT DM ORT DM ORT DM ORT DM ORT DM ORT DM ORT DM ORT DM ORT DM ORT DM ORT

Page description Title page Title page Table of contents: (1 - 18) VIEW OF DRIVE MODULE VIEW OF DRIVE MODULE MAINS CONNECTION TRANSFORMER UNIT POWER SUPPLY CONTACTOR BOARD POWER UNITSERVO DISCONNECTOR AXIS COMPUTER UNIT AXIS COMPUTER UNIT VIEW OF DRIVE MODULE RECTIFIER AND BLEEDER FAN UNIT ADDITIONAL AXIS 1-3, DRIVE UNIT NO 7 ADDITIONAL AXIS 1-3, DRIVE UNIT NO 8 ADDITIONAL AXIS 1-3, DRIVE UNIT NO 9

Page supplementary field Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved

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Table of contents: (1 - 18)

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A41.1.4 A41.1 A41.3 G1 Q1 H1 A41.2

A41.1.3

K43

K42

K44

Z1

A43 F1 K41 F2

P1 (opt duty time counter)

XP0 XS25 XS41 XS1 XS7


A42

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XS2
Lab/Office:

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VIEW OF DRIVE MODULE

Document no.

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02

A42 Axis computer unit

A43 Contactor unit

X7
X11

X5 X8 X9

X9

X6 X4

X22

X2 X3 X8
X11 X12

X21

X23 X10

X24

X5

X1

X4

X10

X6 X1

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VIEW OF DRIVE MODULE

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02

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1 2 3

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-Q1
AWG10 BK AWG10 BK

-XP0

/7.3 / -L1 /7.3 / -L2 /7.4 / -L3

-110 -111 -112

AWG10 BK
2 1 AWG10 BK 4 3 AWG10 BK 6 5

-101 -102 -103

1 2 AWG10 BK 3 4

TRANSFORMER UNIT

EPLAN
Lab/Office:

AWG10 GNYE 4

-F6

-Z1
5

107 108 109

2 4 6

1 3 5

4 6

3 5

MAINS CONNECTION
Status: Document no.

OPTION: CIRCUIT BRAKER

OPTION: MAINS LINE FILTER

Approved

3HAC020538-002 02

= DM Plant: + ORT Location: Sublocation: + Rev. Ind Page 6 Next 7 Total 18

/8.4 / -230V AC1 /8.4 / -230V AC2

/10.7 / -L1 /10.7 / -L2 /10.7 / -L3

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=DM +T1

200V 220V

TRANSFORMER UNIT

-X2

1 2

400V 230V 440V 230V 480V 500V 525V 600V

-X1

200V

-119 -120 -121

AWG10 BK AWG10 BK

220V 3

-X10

400V AWG10 BK 440V 480V 500V 525V 600V

-113 -114 -115

AWG10 BK AWG10 BK

-110 -111

BK BK BK

-L1 / /6.4 -L2 / /6.4 -L3 / /6.4

A1 A2

AWG10 BK B1 B2

MAINS CONNECTION

-112

=DM +L1
200V 220V 400V 440V 480V 2 500V 525V 600V

AWG10 GNYE

EPLAN -X2
F2 1

-X1

-L1
F1

AWG10 GNYE

Lab/Office:

F4

F3

2 3

F6

F5

ONLY FOR IRB 6600-7600

TRANSFORMER UNIT
Status: Document no.

=DM +T2
6

TRANSFORMER UNIT

-X2
230V 400V

-X1

T2 USED FOR: DIRECT POWER SUPPLY IRB6600 400-480V IRB7600 480V

IN

Approved

440V 480V

113 114 115

3HAC020538-002 02

= DM Plant: + ORT Location: Sublocation: + Rev. Ind Page 7 Next 8 Total 18

/11.2 / -24V DRIVE

/11.2 / -0V DRIVE

/15.2 / -24V DRIVE

/15.2 / -0V DRIVE

/9.2 / -24V DRIVE /9.2 / -0V DRIVE

/9.2 / -24V BRAKE /9.2 / -24V BRAKE


/9.2 / -+24V COOL

CONTACTOR UNIT

/9.2 / -0V BRAKE /9.2 / -0V BRAKE /9.2 / -0V COOL


/15.2 / -+24V COOL /15.2 / -0V COOL

Lab/Office:

/11.2 / -+5V

/11.2 / -ACOK /11.2 / -BRAKEOK


/11.2 / -TEMPOK

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=DM +G1

-X2

BK BN

1 4

DRIVE POWER SUPPLY

AXIS COMP. UNIT MAIN SERVO DRIVE UNIT CONTACTOR UNIT

RD
2

OG
5

-463 -464

BU 3 BU 6 3

-X3

-465 -466 -469 -467 -468 -470 -461 -462

AWG16 AWG16 BU

1 2

AWG16 3 AWG16 5

-F2

-X1

AWG16 BU 6 AWG16 7 AWG16 BU 4

-152
1

AWG16 BK

-230V AC1 / /7.2 -230V AC2 / /7.2

EPLAN

-153
5

BK 14 11

-156

BK

AWG16 BU 8

MAIN SERVO DRIVE UNIT AXIS COMP. UNIT

-X4

BK BN

1 2

RD
3 5

OG
4

POWER SUPPLY
Status: Document no.

-K41
A2 A1

-155

-154
6

-141
AWG20 BU 2 1

-140
AWG20 BU 2 GND

AWG16 BK 1

AWG16 BK

-XS25

-K41.X1

Approved

GND

230V AC2

230V AC1

0V

AC_ON

3HAC020538-002 02

CONTROL MODULE X20

CONTROL MODULE A21.X7 PANEL BOARD

= DM Plant: + ORT Location: Sublocation: + Rev. Ind Page 8 Next 9 Total 18

CONTACTOR UNIT
=DM +A43
BU PTC1 1 0V BRAKE 2 PTC1 ret 3 0V BRAKE 4 2 3 4 0V COOL 1 +24V COOL 2 FAN1 3 FAN1 ret 4 2 4 2 1 BU

DRIVE POWER SUPPLY -X6 -X5

/8.3 / -0V DRIVE

-464

/8.3 / -24V DRIVE

-463

RUN CH1 1

-X1

RUN CH1 RET

RUN CH2

CONTROL MODULE A21.X7

RUN CH2 RET

-X10

LIM2 ch1 1 3

-X22
24VDrive 0VDrive

LIM2 ch2

LIMIT SWITCH 2 EXTERNAL AXIS

LIM2 ch2 ret

LIM2 ch1 ret

24VDrive

-X23
1 +24V COOL 3 FAN2 4 2 FAN2 ret 4 3 2 1

0V COOL

-X11

LIMIT OVERRIDE

LIM1 ch1 1 3 LIM2 4 LIM1 2

-X21
0VDrive

OPTION: DUTY TIME COUNTER


-P1

LIM1 ch2

-X12
1

-491

AWG20 BU

+24V

LIMIT SWITCH 1 CONTROL CABLE

LIM1 ch2 ret

LIM1 ch1 ret

h
-492
AWG20 BU 2 0V

ENABLE2_1 5 INTERLOCKING 6 7 8

-X1

ENABLE2_1Ret

CONTROL MODULE A21.X7

SPEED

0V

RUN_CH2

RUN_CH1

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OG 5 7 8

AXIS /11.2 / -RS485+ /11.2 / -RS485COMPUTER /11.2 / -0V ENABLE2 /11.2 / -ENABLE2
K1 4

WHOG

24V COOL

SELF1

LOCK1A

LOCK2B

0V COOL

RUN_CH1

0V COOL

CONTINUATION NEXT PAGE


Lab/Office:

Latest revision:

0V COOL

/8.3 / -24V BRAKE /8.4 / -0V COOL /8.4 / -+24V COOL /8.3 / -24V BRAKE /8.4 / -0V BRAKE /8.4 / -0V BRAKE
1 2 3 4 5

BRAKE

-466 -470 -469 -465 -467 -468

AWG16 BU

RUN_CH2

AWG16 BU

SELF2

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PAN_CH2

AWG16 BU

-X7

AWG16 BU

AWG16 BU

DRIVE POWER SUPPLY

AWG16 BU

PAN_CH1

WHBU

24V COOL

BRAKE CTRL

BU

24V COOL

AWG24

-X4

K2

Status:

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EPLAN

CONTACTOR BOARD

Document no.

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/14.4 / -L12 /14.5 / -L22 /14.5 / -L32

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=DM +A43

-X8

-K42
A2 A1

-471 -472

AWG20 BU AWG20 BU

0V COOL

CONTACTOR UNIT

RUN CH1
1

-K44
AWG20 BU 44 43 A2 1 A1

-473 -474

AWG20 BU 6 AWG20 BU 5

0V COOL

BRAKE

-K43
A2 A1

-475 -476

AWG20 BU 4 AWG20 BU 3

0V COOL

RUN CH2 -X3

-451 -452
2

AWG20 BU AWG20 BU

24V

BRAKE_FB
6

-479 -493 -480 -481 -494


AWG20 BU 44 43

AWG20 BU 5 AWG20 BU 4 AWG20 BU 10 AWG20 BU 9 AWG20 BU 3 AWG20 BU 2 AWG20 BU 7 AWG20 BU 8

0V SELF1 24V SELF2 LOCK1B LOCK1A


4

-H1

STATUS DIOD

-482 -483
22 21

-484 -485
22 21

EPLAN
EXT MON 1A

LOCK2A LOCK2B

-486

-X24

CUSTOMER CONNECTION

Lab/Office:

EXT MON 1B EXT MON 2A EXT MON 2B

&
0V

EXTCONT

34

33

3 4

34

33

24V DRIVE
6

PTC2
1

PTC2 0V
2 EXT. LAMP BRAKE REL.

-X40
1 2

-445 -447 -448 -446 -449 -450

AWG16 BU

-X9

AWG16 BU 4 3 AWG16 BU

-490

BU 14 13

-489

BU 13 14

-487

AWG16 BU

24V BRAKE

POWER UNIT SERVO DISCONNECTOR


Status: Document no.

BRAKE REL. 3 BRAKE PB 4 EXT. BRAKE REL. 5 EXT. BRAKE PB 6

AWG16 BU 22 21 AWG16 BU 6 5

-488

AWG16 BU 2

24V BRAKE BRAKE PB


3

CONTROL CABLE AND OPTION: EXTERNAL AXIS

AWG16 BU

-F1

-128 -129 -130

AWG10 BK 2 1 2 1 AWG10 BK 4 3 4 3 AWG10 BK 6 5 6 5

-122 -123 -124

BK 2 BK 4 BK 6

-119
1

AWG10 BK AWG10 BK AWG10 BK

-L1 / /7.3
7

I>

Approved

-120
3

RECTIFIER

-L2 / /7.3 -L3 / /7.3

I> I>

-121
5

3HAC020538-002 02

= DM Plant: + ORT Location: Sublocation: + Rev. Ind Page 10 Next 11 Total 18

AXIS COMPUTER UNIT


=DM +A42

MAIN SERVO DRIVE UNIT -X1


1

=DM +A41.1

DRIVE POWER SUPPLY BK


2

/8.2 / -0V DRIVE


BN

/8.2 / -24V DRIVE -X11


AWG26 BK 1 BN 2 2 BK 6 3 RD 7 4 11 OG 12 12 BK 3 YE 4 2 8 3 9 6 13 AWG24 BU 14 BK 5 5 OG 7 WHOG 8 5 4
WHBU

-X1
1

/8.5 / -+5V
BK
1

-X10
2

+FRAME RECEIVER -FRAME RECEIVER +CLK RECEIVER

DRIVE POWER SUPPLY BN

/8.5 / -ACOK RD
6

/8.5 / -BRAKEOK
OG
BK 11 7

-CLK RECEIVER +DATA RECEIVER -DATA RECEIVER +FRAME TRANSMITTER 3 -FRAME TRANSMITTER 4 +CLK TRANSMITTER 8 -CLK TRANSMITTER 9 +DATA TRANSMITTER 13 -DATA TRANSMITTER 14 GND

/8.5 / -TEMPOK

TX+ 1 BK GN BK BU

-X2

TX-

CONTROL MODULE A32.A9 RCC

RX+

RX-

/9.2 / -RS485+

-X6

CONTACTOR UNIT

/9.2 / -RS485-

/9.2 / -0V ENABLE2

/9.2 / -ENABLE2

-X9
RXD TXD 3 0V 5 2

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AXIS COMPUTER UNIT


=DM +A42
MRCO1 1 MRCO1_N 2 MRCI1 4 MRCI1_N GND_O2 0V 6 24V_SMB1 2 0V 3 IN 2 0V 4 5 IN 1 6 GND_01 MRCO2 7 24V_EXT1 MRCO2_N 8 OUT 2 MRCI2 9 MRCI2_N 10 GND_I2 0V 11 24V_SMB2 12 GND_I1 0V 13 0V 14 OUT 1 15 9 J 3 G 7 F 6 E 5 D 4 C 2 B 1 9 J 3 G 7 F E 1 24V_EXT2 5 C D B A

DRIVE MODULE -X4

-XS2

-X8

CONTROL SIGNAL

-X5

-XS41
A

PROCESS I/O

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EXT. AXIS SIGNAL
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3 UNITS FOR IRB140, IRB1400, IRB2400, IRB340 6 UNITS FOR IRB4400, IRB940, IRB6600, IRB7600

A41.1 MAIN SERVO DRIVE UNIT

A41.1.4 SINGLE SERVO DRIVE UNIT OPTION: EXT AXIS 8 A41.1.3 SINGLE SERVO DRIVE UNIT OPTION: EXT AXIS 7 A41.2 RECTIFIER

DC-BUSBAR
A41.2 RECTIFIER

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A41.1.3 SINGLE SERVO DRIVE UNIT OPTION: EXT AXIS 7 A41.1.4 SINGLE SERVO DRIVE UNIT OPTION: EXT AXIS 8 A41.1.5 SINGLE SERVO DRIVE UNIT OPTION: EXT AXIS 9

DC-BUSBAR

A41.1 MIAN SERVO DRIVE UNIT

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02

CONTACTOR UNIT
-L12 / /10.7 -L22 / /10.7
AWG10 BK

AWG10 BK

-128

-129

-130

AWG10 BK AWG10 GNYE

MAIN SERVO DRIVE UNIT RECTIFIER


=DM +A41.2

-L32 / /10.7

=DM +A41.1

-X32
1 2 3 4

BLEEDER -X33
-132
1

AWG12 BK 1

Spare BN 1 2 6 7 11 12 3 4 8 9 13 14 5 10 2 BK RD BK OG BK YE BK GN BK BU BK VT

-X2
BK

AWG26

-X30

-R1.1
2

Spare

+24V

0V

-133

AWG12

DATA_TO_DRIVE

DATA_TO_DRIVE_N

11

ENABLE

12

ENABLE_N

CLK

CLK_N

DATA_TO_RECT

CAPACITOR UNIT -X31


1

DATA_TO_RECT_N

13

0V

14

=DM +A41.3 -69 -70


2 AWG20 BU AWG20 BU

+5V

-X34
1 2

10

-71
3

AWG20 BU 3

-72
4

AWG20 BU 4

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MAIN SERVO DRIVE UNIT


=DM +A41.1

/8.2 / -0V DRIVE


OG
1

DRIVE POWER SUPPLY

-X3 FAN UNIT


=DM +E1

/8.2 / -24V DRIVE


2

RD

+24V AWG16 BU 8 8 1 AWG16 BU 2 T1 4 4 2 1

-X5
1 1

-X5
BK VT

-X1
8 1

/8.4 / -+24V COOL

-461

-X4

-X4

+24V

-354 -350

DRIVE POWER SUPPLY

/8.4 / -0V COOL

-462

OG
3

-352

M
3

M
3 BU BN
2

M
3 -351 -355

1 -E41

1 -E42

1 -E43

1 -E44

M
3

0V 0V 2 T2 T3 T4 6 3 5 5 3 6 7 7 2

7 4 5 6

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YE RD GN

-353 -356 -357

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MAIN SERVO DRIVE UNIT ADDITIONAL AXIS 1-3, DRIVE UNIT NO 7


=DM +A41.1.3

SINGLE SERVO DRIVE UNIT

=DM +A41.1

-X7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 19 20 21 22 15 23 18 24 25 26 26 24 25 23 18 22 15 20 21 17 19 14 16 12 13 11 10 9 8 7 6 5 4 3 2 1

-X20

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MAIN SERVO DRIVE UNIT


=DM +A41.1.4

ADDITIONAL AXIS 1-3, DRIVE UNIT NO 8 SIGNLE SERVO DRIVE UNIT

=DM +A41.1

-X8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 19 20 21 22 15 23 18 24 25 26 26 24 25 23 18 22 15 20 21 17 19 14 16 12 13 10 11 9 8 7 6 5 4 3 2 1

-X20

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ADDITIONAL AXIS 1-3, DRIVE UNIT NO 9 SINGLE SERVO DRIVE UNIT


=DM +A41.1.5

MAIN SERVO DRIVE UNIT

=DM +A41.1

-X9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 19 20 21 22 15 23 18 24 25 26 26 24 25 23 18 22 15 20 21 17 19 14 16 12 13 10 11 9 8 7 6 5 4 3 2 1

-X20

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EPLAN

The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.
In no event shall ABB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document.
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Copyright 2004 ABB All right reserved.

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ABB Automation Technologies AB Robotics SE-721 68 Vsters Sweden
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EPLAN

Phone :

: : : 3HAC020538-002_Cables for 6600-7600 :


: 2004-09-23 : : : : : : :
2004-02-16

Customer Robot serial number(s) Drawing number Drawing version

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Manufacture Type Type of installation Control cabinet Mains voltage Supply Control voltage Year of construction

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Table of contents
Date 2004-09-09 2004-09-09 2004-09-23 2004-09-23 2004-09-23 2004-09-23 2004-09-23 2004-09-23 2004-09-23 2004-09-23 2004-09-23 2004-09-23 2004-09-23 2004-09-23 2004-09-23

DIN_INV_30_1

Plant

Location

Editor

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DOKUMENTEDKB DOKUMENTEDKB DOKUMENTEINV DM ORT DM ORT CM ORT CM ORT DM ORT DM ORT CM ORT CM ORT CM ORT CM ORT DM ORT DM ORT

Page description Title page Title page Table of contents: (1 - 15) SERVO DRIVE SYSTEMIRB 6600-7600 CONTROL CABLEIRB 6600-7600 POSITION SWITCH 1IRB 6600-7600 POSITON SWITCH 2/3IRB 6600-7600 POSITION SWITCH 2/3 AND COOLING AXIS 1,2 COOLINNG AXIS 1,2 CUSTOMER POWER/SIGNALSIRB 6600-7600 CUSTOMER POWER/SIGNALS/DeviceNetIRB 6600 CUSTOMER POWER/SIGNALS/IBSIRB 6600-7600 CUSTOMER POWER/SIGNALS/PROFIBUSIRB 6600EXTERNAL AXIS no 7 EXTERNAL AXIS no 8

Page supplementary field Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved Approved

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=DM +A41.1
34
1

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-XS/XP1

-R1.MP
17 24 19 26 18 25 1 10 2 23 32 21 30 22 31

-X11

GNRD OGGN

-400 -401

AWG12 AWG12 AWG12 AWG12 AWG12 AWG12

BK BK

17 24 BK

BN 19 OGBU 26 GNWH 18 OGBK 25

-402 -403 -404 -405

BK 4 BK 5 BK 6

MAIN SERVO DRIVE UNIT

-X12

BKBU 1 BKRD 10 BKGN 2

-418 -420 -422

AWG12 AWG12 AWG12

BK BK BK

DC-BUSBAR

1 2 3 4 5 6

-X13

GYWH 23 BNWH 32 GY 21 BNGN 30 GYRD 22 BNRD 31

-406 -407 -408 -409 -410 -411

AWG12 AWG12 AWG12 AWG12 AWG12 AWG12

BK BK

1 2

BK 3 BK 4 BK 5 BK 6 4

EPLAN
Lab/Office:

-X14

GYBU 20 GYGN 29 GYBK 28 BU 3 BKWH 4 BNBU 7 BK 14 14 BNBK 5 5 BUBK 6 6 7 4 3 28 29 20

-424 -425 -426

AWG12 AWG12 AWG12

BK BK BK

1 2 3 4 5 6 5

-X15

-412 -413 -414 -415 -416 -417

AWG12 AWG12 AWG12 AWG12 AWG12 AWG12

BK BK

1 2

BK 3 BK 4 BK 5 6 BK 6

SERVO DRIVE SYSTEM IRB 6600-7600


Status: Document no.

-X16

BUWH 9 BUGN 16 BURD 8 8 AWG10 AWG10 GNYE GNYE 16 9

-428 -430 -432

AWG12 AWG12 AWG12

BK BK BK

1 2 3 4 5 6 7

Approved

3HAC020538-002 02

DRIVE MODULE

MANIPULATOR

= DM Plant: + ORT Location: Sublocation: + Rev. Ind Page 4 Next 5 Total 15

AXIS COMPUTER UNIT MANIPULATOR

=DM +A42

DRIVE MODULE

-X4 SDI SDI-N


B B A A

-XS/XP2

-R1.SMB

SDO
C D E F G H J K F E D C

SDO-N
0V 24V

SERIAL MEASUREMENT BOARD

BAT BR
G

BAT BR
H

0V
J

BATSUP
K

EXT.LAMP
L L

EXT.LAMP

-Y1 -C1

-X40
EXT LAMP BRAKE PB 11 BRAKE REL. 13 BRAKE REL.

-433
AWG16 BU AWG16 BU AWG16 BU AWG16 BU

34 0,00

-434 -435 -436

-XS/XP1

OGRD OG

-R1.MP
11 13

BRAKE PB

DRIVE MODULE XP40

BRAKE RELEASE BRAKE RELEASE

CONTACTOR UNIT
0V BRAKE PTC PTC 0V 0V BRAKE

=DM +A43 -437


AWG16 BU 12 AWG16 BU 27 AWG16 BU 15 AWG16 BU

-X5
-439 -440 -438

OGWH 12 PKBK 27
PKWH

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0V BRAKE 0V BRAKE PTC 0V PTC


15

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CONTROL CABLE IRB 6600-7600

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Customer Connection
AWG 24 OG

CONTROL MODULE

MANIPULATOR IRB 6600, 7600 -XS/XP8


-R1.SW1
A A B C D E F G H J K L M

-XP/XT8.1
OG OG B OG C OG D OG E OG F OG G OG H OG J OG K OG L OG M

-601

A 1

-602

-603

-604

-605

-606

-607

-608

-609

-610

10

-611

11

-612

12

-XP/XT8.2
OG N OG P OG R OG S OG T OG U OG V OG
W W

-613

13

N P R S T U V

-614

14

-615

15

-616

16

-617

17

-618

18

-619

19

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-620
OG X OG Y OG Z OG a

20

-621

21

X Y Z a

-622

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-623

23

-624

24

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Customer Connection
AWG 24 OG

CONTROL MODULE -XS/XP58


-R1.SW23
A A B C D E F G H J K L M

MANIPULATOR IRB 6600, 7600

-XP/XT58.1
601 602
B

603
C

604
D

605
E

606
F

607
G

608
H

609
J

610
K

10

611
L

11

612
M

12

-XP/XT58.2
613
T T U V
W

13

614
U

14

615
V

15

616
W

16

617
X X Y Z a b c d e

17

618
Y

18

619
Z

19

620
a

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621
b

21

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c

22

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d

23

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e

24

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MANIPULATOR
=DM +BOX -R1.XP.SW23
A B C D E F G H J K L M T U V U V
W

R1.XS.SW23 -R1.SW23
A B C D E F G H J K L M T

DRIVE MODULE
W

X Y Z a b c d e S e S c a Y

X Z

CONTACTOR UNIT

=DM +A43

b d

-X10

24V FAN 1 0V FAN 1

-R1FAN.SW23
N P N P R R

-X11 24V FAN 2

T1

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h h

0V FAN 2
T2

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MANIPULATOR

-R1.SW23
A B C D E F G H J K L M T U V

DRIVE MODULE

X Y Z a b c d e S

CONTACTOR UNIT

=DM +A43

-X10

24V FAN 1
N

0V FAN 1
P

-X11 24V FAN 2

T1
R

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0V FAN 2
g

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h

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CONTROL MODULE

Customer Connection
AWG 18 OG

-XS/XP13 -R1.CP/CS
A1 D1 CP5 A2 D6 CP6 A3 D3 CP7 A4 D4 CP1 A5 D5 CP2 A6 D2 CP3 A7 D7 CP4

MANIPULATOR IRB 6600-7600

-XP/XT6
670 671 672 673 674 675 676
AWG 14 OG AWG 24 OG

-XP/XT5.1
B1 B2 B11 B12 B13 B14 B15 B16 B18 B19 B20 B21

CS B1 B2 B11 B12 B13 B14 B15 B16 B18 B19 B20 B21 CS CS CS CS CS CS CS CS CS CS CS

10

11

677 678 679 680 681 682 683 684 685 686 687 688

12

-XP/XT5.2
CS C1 C2 C3 C4 C3 C4 C1 C2 CS CS CS

19

20

23

695 696 699 700

24

CS B7 B8 B9 B10 B3 B4 B5 B6 B5 B6 B3 B4 B9 B10 B7 B8 CS CS CS CS CS CS CS

13

14

15

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16

17

18

21

689 690 691 692 693 694 697 698

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CONTROL MODULE

Customer Connection
AWG 18 OG

-XS/XP13 -R1.CP/CS
CP4 CP5 A2 D6 CP6 A3 D3 CP7 A4 D4 A1 D1

MANIPULATOR IRB 6600-7600

-XP/XT6
670 671 672 673

-XP/XT5.1
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12

AWG 24 OG CS B11 B12 B13 B14 B15 B16 B18 B19 B20 B21 B9 B10 CS CS CS CS CS CS CS CS CS CS CS

10

11

677 678 679 680 681 682 683 684 685 686 687 688

12

-XP/XT5.2
CS F5 F6 F7 F8 F9 F10 F11 F12 A9 A10 A11 A12 B24 B25 A5 A6 CS CS CS CS CS CS CS

13

14

15

16

17

18

19

689 690 691 692 693 694 695 696

20

DEVICE NET ADAPTER


CAN_L
F4 A4 CAN_L

=CM +A35

-J1

120 Ohm

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CAN_H
F3 A3

CAN_H

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701 +24V CAN
F1 B22 0V F2 B23 +24V CAN

CONTROL MODULE G4.X2 702 0V

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CONTOL MODULE
AWG 18 OG

Customer Connection

-XS/XP13 -R1.CP/CS
A1 D1 CP5 A2 D6 CP6 A3 D3 CP7 A4 D4 CP4

MANIPULATOR IRB 6600-7600

-XP/XT6
670 671 672 673

-XP/XT5.1
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12

AWG 24 OG CS1 B11 B12 B13 B14 B15 B16 B18 B19 B20 B21 B9 B10 CS2 CS11 CS12 CS13 CS14 CS15 CS16 CS17 CS18 CS19 CS20

10

11

677 678 679 680 681 682 683 684 685 686 687 688

12

-XP/XT5.2
CS7 F5 F6 F3 F4 F2 F11 F12 B23 B24 B25 A3 A4 A5 A6 CS8 CS9 CS10 CS11 CS3 CS4

13

14

15

16

17

18

689 690 691 692 693 694 695

19

DO DO_N DI DI_N GND GND F1 F10 F9 F8 F7 A9 A10 A11 A12 B22

DO DO_N DI DI_N GND

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MANIPULATOR IRB 6600-7600

-XP/XT6
670 671 672 673

-XP/XT5.1
B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12

AWG 24 OG CS B11 B12 B13 B14 B15 B16 B18 B19 B20 B21 B9 B10 CS CS CS CS CS CS CS CS CS CS CS

10

11

677 678 679 680 681 682 683 684 685 686 687 688

12

-XP/XT5.2
CS F3 F4 F7 F8 F9 F10 F11 F12 F1 F2 A9 A10 A11 A12 B24 B25 B22 B23 A3 A4 CS CS CS CS CS CS CS CS CS

13

14

15

16

17

18

19

20

21

689 690 691 692 693 694 695 696 697 698

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RD
F5

RXD/TXD-P
A5

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F6 A6

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SINGLE SERVO DRIVE UNIT -XS/XP7 U


AWG12 BK A1 AWG12 BK A2 AWG12 BK A3 AWG12 BK A4 AWG12 BK A5 AWG12 BK A6

=DM +A41.1.3 4000 4001 4002 4003 4004 4005

-X21 U
W W

V V

CONTACTOR UNIT
PTC
AWG16 BU E1

=DM +A43 4013 4014


AWG16 BU E2 E3 E4 E5 E6

-X24 PTC 0V

0V BRAKE
AWG16 BU

-4012

F9 F10 F11

-X22 LIM2 ch1 LIM2 ch1 ret LIM2 ch2 LIM2 ch2 ret
-4009 -4008 -6007 -4006

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F5 F6 AWG16 BU AWG16 BU F7 F8

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1

U
2

W
3

W
4

V
5

V
6

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Page description Title page Title page Table of contents: (1 - 9) SERVO DRIVE SYSTEMIRB 4400 CONTROL CABLEIRB 4400 CUSTOMER POWER/SIGNALIRB 4400 POSITION SWITCHIRB 4400 EXTERNAL AXIS no 7 EXTERNAL AXIS no 8

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=CAB +A41.1

-XS/XP1

-R1.MP
M1R A1 A2 A5 A6 A3 A4 D6 D8 D10 M4R B3 M4T B5 M4S B4 M4R D11 D13 M2R A7 A8 A11 A9 A12 A10 M2R M2T M2T M2S M2S M4S M4T D12 M1R M1T M1T M1S M1S M1R M1S M1T

-X11

BKBU BKGN BUGN BURD BKWH BK BKRD BUBK BUWH D8 A4 A6 A2

AWG16 AWG16 AWG16 AWG16 AWG16 AWG16

MAIN SERVO DRIVE UNIT

A1 A5 A3 D6 D10

2 3 4 5

-400 -401 -402 -403 -404 -405

-X12

GYWH B3 OGGN B5 OGBK B4 GYRD GY OGBU D12 D11 D13

-418 -420 -422

AWG16 AWG16 AWG16

BK BK BK

DC-BUSBAR

1 2 3 4 5 6

-X13

BU BNBK BNRD BNWH BNBU BNGN A12 A10 A8 A11 A9 A7

AWG16 AWG16 AWG16 AWG16 AWG16 AWG16

1 2 3 4 5

-406 -407 -408 -409 -410 -411

6 4

-X14

EPLAN
B6 B8 B7 Lab/Office: D15 A14 B2 A15 C13 A16 C14 D14 D16 A13 B1

M5R M5T M5S M5R M5S M5T

OGWH B6 PKGN B8 PKBK B7 OGRD OG PKBU D15 D14 D16

-424 -425 -426

AWG16 AWG16 AWG16

BK BK BK

1 2 3 4 5 6 5

-X15

M3R M3R M3T M3T M3S M3S

BN GNRD GYBU GYGN GNWH GYBK WHBU WHGN WHRD A16 C14 A14 B2 A15 C13 A13 B1

AWG16 AWG16 AWG16 AWG16 AWG16 AWG16

1 2 3 4 5

-412 -413 -414 -415 -416 -417

SERVO DRIVE SYSTEM IRB 4400


Status: Document no.

C15 M6R B9 M6T B11 M6S B10 C3 PK PKWH PKRD

C15

-X16

-428
B9

AWG16 AWG16 AWG16

BK BK BK

1 2

-430
B11 AWG10 AWG10 B10

3 4

-432

5 6 7

C4

Approved

C5 C6 C7 C8 C9 C10 C12

DRIVE MODULE

C11

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AXIS COMPUTER UNIT DRIVE MODULE MANIPULATOR

=CAB +A42 -XS/XP2


A B C D E E D C B A

-X4

-R1.SMB

SDI SDI-N SDO SDO-N 0V


24V

6 F G H J K L L J K G H F

SERIAL MEASUREMENT BOARD

0V BATSUP BATLD

54 0,00 Ext. Lamp C16 Brake PB B16 Brake Release B12 Brake Release B13

-XS/XP40
-433
AWG16 BU AWG16 BU AWG16 BU AWG16 BU

-XS/XP1

WH

-R1.MP
C16 VT B16 RDBK B12 RDBU B13

-434 -435 -436

DRIVE MODULE X40

CONTACTOR UNIT
0V Brake B14 PTC C2 PTC 0V C1 0V Brake B15

=CAB +A43
-438
AWG16 BU AWG16 BU AWG16 BU AWG16 BU

-X5
-439 -440 -437

RDGN B14 VTGN C2 VTBU C1 VTWH B15

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LIM 1A LIM 2A LIM 2B LIM 1B

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RDWH

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1) -443 -444
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D1 VTBK D3 AWG16 BU D4 VTRD

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=CAB-XS/XP5 =CAB-R1.CP/CS
A1 B1 C1 D1 A2 B2 C2 D2 A3 B3 C3 D3 D1 A2 B2 C2 D2 A3 B3 C3 D3 C1 B1 A1 CPA CPB CPC CPD CPE CPF CPJ CPK CPL CPM

MANIPULATOR IRB 4400

=CAB-XP/XT6

10

11

648 649 650 651 652 653 654 655 656 657 658 659

12

=CAB-XP/XT5.1
B5 C5 D5 A6 B6 C6 D6 A7 B7 C7 D7 A8

AWG 24 OG CSA B5 C5 D5 A6 B6 C6 D6 A7 B7 C7 D7 A8 CSB CSC CSD CSE CSF CSG CSH CSJ CSK CSL CSM

10

11

625 626 627 628 629 630 631 632 633 634 635 636

12

=CAB-XP/XT5.2
CSN B8 C8 D8 A9 B9 C9 D9 A10 B10 C10 C10 D10 B8 C8 D8 A9 B9 C9 D9 A10 B10 C10 D10 CSP CSR CSS CST CSU CSV
CSW

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14

15

16

17

18

19

20

CSX CSY CSZ

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22

637 638 639 640 641 642 643 644 645 646 647

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OG A OG B B C D E F J K L M G H OG C OG D OG E OG F OG J OG K OG L OG M OG G OG H

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=CAB-R1.SW
A 1

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10

11

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=CAB +A41.1.3
-4000 -4001 -4002 -4003 -4004 -4005

-X21 U
W W

V V

CONTACTOR UNIT
PTC
AWG16 BU E1 AWG16 BU E2 E3 E4 E5 E6

=CAB +A43
-4013 -4014

-X24 PTC 0V

0V BRAKE
AWG16 BU

-4012

F9 F10 F11

-X22 LIM2 ch1 LIM2 ch1 ret LIM2 ch2 LIM2 ch2 ret

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F5 F6

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=CAB +A41.1.4
4000 4001 4002 4003 4004 4005
1

U
2

W
3

W
4

V
5

V
6

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32 0,00

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MAIN SERVO DRIVE UNIT

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9 11 13 3

-X17

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-400 -402 -404

AWG16 BK AWG16 BK

A11 A9 A7

AWG16 BK 3 AWG16 BK 4 AWG16 BK 5 AWG16 BK 6

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A B C D E E D C B A

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SDI SDI-N SDO SDO-N 0V


24V

6 F G H J K L L J K H G F

SERIAL MEASUREMENT BOARD

0V BATSUP BATLD

32 0,00 Ext. Lamp C7 Brake PB B16 Brake Release B12 Brake Release B13

-XS/XP40
-433
AWG16 BU AWG16 BU AWG16 BU AWG16 BU BNGN BNRD GNWH GY

-XS/XP1

-R1.MP
C7 B8 C9 C8

DRIVE MODULE X40


-434 -435 -436

CONTACTOR UNIT
0V Brake B14 PTC C2 PTC 0V C1 0V Brake B15

=DM +A43 -438


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AWG 24 OG

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625
B5 A

-XP/XT5
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A 1

CSA CSB

626
C5 B

627
D5 C

CSC CSD
A6 D

628 629
B6 E

CSE CSF
C6 F

630 631
D6 G

CSG
CSH
A7 H

632 633
B7 J

CSJ CSK
C7 K

634 635
D7 L

10

CSL

11

636
A8 M

CSM

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SINGLE SERVO DRIVE UNIT -XS/XP7 U


AWG12 BK A1 AWG12 BK A2 AWG12 BK A3 AWG12 BK A4 AWG12 BK A5 AWG12 BK A6

=DM +A41.1.3 -4000 -4001 -4002 -4003 -4004 -4005

-X21 U
W W

V V

CONTACTOR UNIT
PTC
AWG16 BU E1 AWG16 BU E2 E3 E4 E5 E6

=DM +A43 -4013 -4014

-X24 PTC 0V

0V BRAKE
AWG16 BU

-4012

F9 F10 F11

-X22 LIM2 ch1 LIM2 ch1 ret LIM2 ch2 LIM2 ch2 ret
-4009 -4008 -4007 -4006

AWG16 BU F1 AWG16 BU F4 AWG16 BU F2 AWG16 BU F3

-XS40
EXT. LAMP BRAKE REL. BRAKE REL. BRAKE PB

F5 F6 AWG16 BU AWG16 BU F7 F8

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SINGLE SERVO DRIVE UNIT -XS/XP7 -X21 U


AWG12 B1 AWG12 B2 AWG12 B3 AWG12 B4 AWG12 B5 AWG12 B6

=DM +A41.1.4 -4000 -4001 -4002 -4003 -4004 -4005


1

U
2

W
3

W
4

V
5

V
6

FOR 9 AXIS -XS/XP7 -X21 U U


2

SINGLE SERVO DRIVE UNIT


-4000 -4001 -4002 -4003 -4004 -4005
AWG12 C1 AWG12 C2 AWG12 C3 AWG12 C4 AWG12 C5 AWG12 C6

=DM +A41.1.5
1

W
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5

V
6

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Page description Title page Title page Table of contents: (1 - 9) SERVO DRIVE UNITIRB 2400 CONTROL CABLEIRB 2400 CUSTOMER POWER/SIGNALIRB 2400 POSITION SWITCHIRB 2400 EXTERNAL AXIS no 7 EXTERNAL AXIS no 8-9

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32 0,00

-XS/XP1

MAIN SERVO DRIVE UNIT

-R1.MP
M1R A1 M1S A2 M1T A3 M2T D2 M2S D1 M2R A4 M4R A10 M4S A9 M4T A8 M6T B10 M6S D7 M6R D8

-X17

BKBU BKGN

-400 -402

AWG14 AWG14 AWG14 AWG14 AWG14 AWG14

BK BK

A1 A3 BK

BKRD A5 BUBK A11 BK BKWH A7

-404 -410 -408 -406

BK 4 BK 5 BK 6

A9

-X18

BU B3 BNBK B4 BNBU B5 GNWH B11 GNRD BN

-418 -420 -422 -432 -430 -428

AWG14 AWG14 AWG14 AWG14 AWG14 AWG14

BK BK

1 2

DC-BUSBAR

BK 3 BK 4 BK 5

B10

BK 6

EPLAN
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-X19

M3R D3 M3S D4 M3T B1 M5T D9 M5S D10 M5R A7

BUGN A13 BURD

-412 -414 -416 -426


B8

1 2

A15

BUWH BNWH BNRD

AWG14 AWG14 AWG14 AWG14

BK 3 BK 4 BK 5 BK 6

B1

-425
B7

BNGN B6

SERVO DRIVE UNIT IRB 2400


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GNYE 6 GNYE

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DRIVE MODULE

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AXIS COMPUTER UNIT DRIVE MODULE MANIPULATOR

=DM +A42

-X4
A B C D E E D C B A

-XS/XP2

-R1.SMB

SDI SDI-N SDO SDO-N 0V


24V

6 F G H J K L L J K H G F

SERIAL MEASUREMENT BOARD

0V BATSUP BATLD

32

-XS/XP40
Ext. Lamp OG OGWH B16 Brake Release B12 Brake Release B13 C7 Brake PB

-433
AW G16 BU AW G16 BU AW G16 BU AW G16 BU

-XS/XP1

-R1.MP
C7 B8

DRIVE MODULE X40


-434 -435 -436

GYBK C9 GYBU C8

CONTACTOR UNIT
0V Brake B14 PTC C2 PTC 0V C1 0V Brake B15

=DM +A43 -438


AW G16 BU AW G16 BU AW G16 BU AW G16 BU

-X5
-439 -440 -437

GYGN C10 OGBU B9 OGBK B2 OGRD B7

-X21
LIM 1A LIM 2A LIM 2B LIM 1B

-441
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CONTROL MODULE
AWG 18 OG

Customer Connection

-XS/XP5 -R1.CP/CS
A1 B1 C1 D1 A2 B2 C2 D2 A3 B3 C3 D3 C3 D3 A3 B3 C2 D2 A2 B2 C1 D1 B1 A1 CPA CPB CPC CPD CPE CPF CPJ CPK CPL CPM

MANIPULATOR IRB 2400

-XP/XT6

10

11

648 649 650 651 652 653 654 655 656 657 658 659

12

-XP/XT5.1
B5 C5 D5 A6 B6 C6 D6 A7 B7 C7 D7 A8

AWG 24 OG CSA B5 C5 D5 A6 B6 C6 D6 A7 B7 C7 D7 A8 CSB CSC CSD CSE CSF CSG CSH CSJ CSK CSL CSM

10

11

625 626 627 628 629 630 631 632 633 634 635 636

12

-XP/XT5.2
CSN B8 C8 D8 A9 B9 C9 D9 A10 B10 C10 C10 D10 D9 A10 B10 C10 D10 B9 C9 D8 A9 B8 C8 CSP CSR CSS CST CSU CSV
CSW

13

14

15

16

17

18

19

20

CSX CSY CSZ

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22

637 638 639 640 641 642 643 644 645 646 647

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CONTROL MODULE

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MANIPULATOR IRB 2400

-XS/XP8
-601
OG A OG B B C D E F J K L M G H OG C OG D OG E OG F OG J OG K OG L OG M OG G OG H

-XP/XT8
-R1.SW
A 1

-602 -603 -604 -605 -606 -607 -608 -609 -610 -611 -612

10

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SINGLE SERVO DRIVE UNIT -XS/XP7 U


AWG12 BK A1 AWG12 BK A2 AWG12 BK A3 AWG12 BK A4 AWG12 BK A5 AWG12 BK A6

=DM +A41.1.3 -4000 -4001 -4002 -4003 -4004 -4005

-X21 U
W W

V V

CONTACTOR UNIT
PTC
AWG16 BU E1 AWG16 BU E2 E3 E4 E5 E6

=DM +A43 -4013 -4014

-X24 PTC 0V

0V BRAKE
AWG16 BU

-4012

F9 F10 F11

-X22 LIM2 ch1 LIM2 ch1 ret LIM2 ch2 LIM2 ch2 ret

-4006 -4007 -4008 -4009

AWG16 BU F1 AWG16 BU F4 AWG16 BU F2 AWG16 BU F3

-XS40
EXT. LAMP

1 BRAKE PB

BRAKE REL.

F5 F6

BRAKE REL.

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SINGLE SERVO DRIVE UNIT -XS/XP7 -X21 U


AWG12 B1 AWG12 B2 AWG12 B3 AWG12 B4 AWG12 B5 AWG12 B6

=DM +A41.1.4 4000 4001 4002 4003 4004 4005


1

U
2

W
3

W
4

V
5

V
6

FOR 9 AXIS -XS/XP7 -X21 U U


2

SINGLE SERVO DRIVE UNIT


4000 4001 4002 4003 4004 4005
AWG12 C1 AWG12 C2 AWG12 C3 AWG12 C4 AWG12 C5 AWG12 C6

=DM +A41.1.5
1

W
3

W
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5

V
6

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DOKUMENTEDKB DOKUMENTEDKB DOKUMENTEINV DM ORT DM ORT CM ORT CM ORT DM ORT DM ORT

Page 1 2 3 4 5 6 7 8 9

Page description Title page Title page Table of contents: (1 - 9) SERVO DRIVE SYSTEMIRB 1400 CONTROL CABLEIRB 1400 CUSTOMER SIGNALSIRB 1400 POSITION SWITCHES EXTERNAL AXIS no 7 EXTERNAL AXIS no 8-9

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32 0,00

-XS/XP1

MAIN SERVO DRIVE UNIT

-R1.MP
M1R A1 M1S A2 M1T A3 M2T D2 M2S D1 M2R A4 M4R A10 M4S A9 M4T A8 M6T B10 M6S D7 M6R D8

-X17

BKBU BKGN

-400 -402

AWG14 BK AWG14 BK

A1 A3 AWG14 BK

BKRD A5 BUBK A11 BK BKWH A7

-404 -410 -408 -406

AWG14 BK 4 AWG14 BK 5 AWG14 BK 6

A9

-X18

BU B3 BNBK B4 BNBU B5 GNWH B11 GNRD BN

-418 -420 -422 -432 -430 -428

AWG14 BK AWG14 BK

DC-BUSBAR

1 2

AWG14 BK 3 AWG14 BK 4 AWG14 BK 5 4 AWG14 BK 6

B10

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-X19

M3R D3 M3S D4 M3T B1 M5T D9 M5S D10 M5R A7

BUGN A13 BURD

-412 -414 -416 -426


B8

1 2

A15

BUWH BNWH BNRD

AWG14 BK 3 AWG14 BK 4 AWG14 BK 5 AWG14 BK 6

B1

-425
B7

BNGN B6

SERVO DRIVE SYSTEM IRB 1400


Status: Document no.

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DRIVE MODULE

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MANIPULATOR

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=DM +A42

-X4
A B C D E E D C B A

-XS/XP2

-R1.SMB

SDI SDI-N SDO SDO-N 0V


24V

6 F G H J K L L J K H G F

SERIAL MEASUREMENT BOARD

0V BATSUP BATLD

-XS/XP40
Ext. Lamp C7 Brake PB B16 Brake Release B12 Brake Release B13

-433
AWG16 BU AWG16 BU AWG16 BU AWG16 BU

-XS/XP1

32 0,00 OG OGWH

-R1.MP
C7 B8

DRIVE MODULE X40


-434 -435 -436

GYBK C9 GYBU C8

CONTACTOR UNIT
0V Brake B14 PTC C2 PTC 0V C1 0V Brake B15

=DM +A43 -438


AWG16 BU AWG16 BU AWG16 BU AWG16 BU

-X5
-439 -440 -437

GYGN C10 OGBU B9 OGBK B2 OGRD B7

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LIM 1A LIM 2A

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4 LIM 2B LIM 1B

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MANIPULATOR IRB 1400

AWG 24 OG

-XS/XP5
625
B5 1

-XP/XT5
-R1.CS
A 1

CSA CSB

626
C5 B

627
D5 C

CSC CSD
A6 D

628 629
B6 E

CSE CSF
C6 F

630 631
D6 G

CSG
CSH
A7 H

632 633
B7 J

CSJ CSK
C7 K

634 635
D7 L

10

CSL

11

636
A8 M

CSM

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CONTROL MODULE

Customer Connection

MANIPULATOR IRB 1400

-XS/XP8
-601
OG A OG B B C D E F J K L M G H OG C OG D OG E OG F OG J OG K OG L OG M OG G OG H

-XP/XT8
-R1.SW
A 1

-602 -603 -604 -605 -606 -607 -608 -609 -610 -611 -612

10

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SINGLE SERVO DRIVE UNIT -XS/XP7 U


AWG12 BK A1 AWG12 BK A2 AWG12 BK A3 AWG12 BK A4 AWG12 BK A5 AWG12 BK A6

=DM +A41.1.3 -4000 -4001 -4002 -4003 -4004 -4005

-X21 U
W W

V V

CONTACTOR UNIT
PTC
AWG16 BU E1 AWG16 BU E2 E3 E4 E5 E6

=DM +A43 -4013 -4014

-X24 PTC 0V

0V BRAKE
AWG16 BU

-4012

F9 F10 F11

-X22 LIM2 ch1 LIM2 ch1 ret LIM2 ch2 LIM2 ch2 ret
-4009 -4008 -4007 -4006

AWG16 BU F1 AWG16 BU F4 AWG16 BU F2 AWG16 BU F3

-XS40

EXT. LAMP F5 F6

1 BRAKE PB

BRAKE REL.

BRAKE REL.

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-4010 -4011

AWG16 BU BU AWG16 F8 F7

BRAKE REL. +24V BRAKE PB

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AWG16 BU AWG16 BU AWG16 BU AWG16 BU AWG10 GNYE Lab/Office:

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FOR 8 AXIS

SINGLE SERVO DRIVE UNIT -XS/XP7 -X21 U


AWG12 B1 AWG12 B2 AWG12 B3 AWG12 B4 AWG12 B5 AWG12 B6

=DM +A41.1.4 -4000 -4001 -4002 -4003 -4004 -4005


1

U
2

W
3

W
4

V
5

V
6

FOR 9 AXIS -XS/XP7 -X21 U U


2

SINGLE SERVO DRIVE UNIT


-4000 -4001 -4002 -4003 -4004 -4005
AWG12 C1 AWG12 C2 AWG12 C3 AWG12 C4 AWG12 C5 AWG12 C6

=DM +A41.1.5
1

W
3

W
4

V
5

V
6

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The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.
In no event shall ABB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document.
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Phone :

: : : 3HAC020538-002_Cables for 140 :


: 2004-09-23 : : : : : : :
2004-04-15

Customer Robot serial number(s) Drawing number Drawing version

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Manufacture Type Type of installation Control cabinet Mains voltage Supply Control voltage Year of construction

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Table of contents
Date 2004-09-09 2004-09-09 2004-09-23 2004-09-23 2004-09-23 2004-09-23 2004-09-23 2004-09-23

DIN_INV_30_1

Plant

Location

Editor

DOKUMENTEDKB DOKUMENTEDKB DOKUMENTEINV DM ORT DM ORT CM ORT DM ORT DM ORT

Page 1 2 3 4 5 6 7 8

Page description Title page Title page Table of contents: (1 - 8) SERVO DRIVE SYSTEMIRB 140 CONTROL CABLEIRB 140 CUSTOMER SIGNALIRB 140 EXTERNAL AXIS no 7 EXTERNAL AXIS no 8-9

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1

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=DM +A41.1

32 0,00

-XS/XP1

-X17

MAIN SERVO DRIVE UNIT

-R1.MP1-3
M1R
13

BUGN BURD

-400 -402

AWG14 BK AWG14 BK

A1

M1S
17 M1T 15 M2T 3 M2S 5 M2R 1

A3 AWG14 BK

BUWH A5 BKRD A11 BKGN BKBU A7

-404 -410 -408 -406

AWG14 BK 4 AWG14 BK 5 AWG14 BK 6

DC-BUSBAR

A9

-R1MP4-6
M4R 6 M4S 9 M4T 12 M6T 3 M6S 2 M6R 1

-X18

BN B3 GNRD B4 GNWH B5 BNBU B11 BNBK BU

-418 -420 -422 -432 -430 -428

AWG14 BK AWG14 BK

1 2

AWG14 BK 3 AWG14 BK 4 AWG14 BK 5 4 AWG14 BK 6

B10

EPLAN
Lab/Office: 7 11 9

B9 AWG14 BK AWG14 BK

-X19

M3R M3S M3T M5T 10 M5S 7 M5R 4

BKWH A13 BK

-412 -414 -416 -426


B8

1 2

A15

BUBK BNWH BNRD

AWG14 BK 3 AWG14 BK 4 AWG14 BK 5 AWG14 BK 6

B1

-425
B7

BNGN B6

SERVO DRIVE SYSTEM IRB 140


Status: Document no.

-424

AWG10 GNYE 6 AWG10 GNYE

Approved

DRIVE MODULE

MANIPULATOR

3HAC020538-002 02

= DM Plant: + ORT Location: Sublocation: + Rev. Ind Page 4 Next 5 Total 8

AXIS COMPUTER UNIT DRIVE MODULE MANIPULATOR

=DM +A42

-X4
A B C D E 3 4 8 5 9

-XS/XP2

-R1.SMB

SDI SDI-N SDO SDO-N 0V


24V

6 F G H J K L 2 6 7

SERIAL MEASUREMENT BOARD

BATSUP BATLD

32 0,00

-XS/XP40
Ext. Lamp C7 Brake PB B16 Brake Release B12 Brake Release B13

-433
AWG16 BU AWG16 BU AWG16 BU AWG16 BU OG GYBU GYBK

-XS/XP1

-R1.H1
1

-434 -435 -436

-R1MP4-6
15 8

DRIVE MODULE X40


OGWH

CONTACTOR UNIT
0V Brake B14 PTC C2 PTC 0V C1 0V Brake B15

=DM +A43 -438


AWG16 BU AWG16 BU AWG16 BU AWG16 BU

-X5
-439 -440 -437

OGRD 13 OGGN OGBU OGBK 14 11

-R1.MP1-3
2

-X21
D2

GY 10 GYWH D1 GYRD D3 GYGN D4 12 18 16

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CONTROL CABLE IRB 140

3HAC020538-002 02

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CONTROL MODULE

MANIPULATOR IRB 140

Customer Connection

AWG 24 OG

-XS/XP5
625
B5

-XP/XT5
-R1.CS
1

CSA CSB

626
C5 9

627
D5 2

CSC CSD
A6 10

628 629
B6 3

CSE CSF
C6 11

630 631
D6 4

CSG
CSH
A7 12

632 633
B7 5

CSJ CSK
C7 13

634 635
D7 6

10

CSL

11

636
A8 14

CSM

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SINGEL SERVO DRIVE -XS/XP7 U


AWG12 BK A1 AWG12 BK A2 AWG12 BK A3 AWG12 BK A4 AWG12 BK A5 AWG12 BK A6

=DM +A41.1.3 -4000 -4001 -4002 -4003 -4004 -4005

-X21 U
W W

V V

CONTACTOR UNIT
PTC
AWG16 BU E1 AWG16 BU E2 E3 E4 E5 E6

=DM +A43 -4013 -4014

-X24 PTC 0V

0V BRAKE
AWG16 BU

-4012

F9 F10 F11

-X22 LIM2 ch1 LIM2 ch1 ret LIM2 ch2 LIM2 ch2 ret
-4008 -4009 -4007 -4006

AWG16 BU F1 AWG16 BU F4 AWG16 BU F2 AWG16 BU F3

-XS40
EXT LAMP BRAKE REL. BRAKE REL. BRAKE PB

F5 F6 AWG16 BU AWG16 BU F7 F8

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EXTERNAL AXIS no 7

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FOR 8 AXIS

SINGLE SERVO DRIVE UNIT -XS/XP7 -X21 U


AWG12 B1 AWG12 B2 AWG12 B3 AWG12 B4 AWG12 B5 AWG12 B6

=DM +A41.1.4 -4000 -4001 -4002 -4003 -4004 -4005


1

U
2

W
3

W
4

V
5

V
6

FOR 9 AXIS -XS/XP7 -X21 U U


2

SINGLE SERVO DRIVE UNIT


-4000 -4001 -4002 -4003 -4004 -4005
AWG12 C1 AWG12 C2 AWG12 C3 AWG12 C4 AWG12 C5 AWG12 C6

=DM +A41.1.5
1

W
3

W
4

V
5

V
6

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3HAC021313-001 (part 2 of 2), rev A, en