IRC5

Product manual
Robot controller
IRC5
Product manual
Robot Controller
IRC5
M2004
Document ID: 3HAC021313-001

Revision: K
© Copyright 2004-2008 ABB. All rights reserved.
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 ABB's 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 2004-2008 ABB All rights reserved.

ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Safety 13
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.3.1 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.4.1 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.5 Safety stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.5.1 Overview of robot stopping functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.5.2 What is an emergency stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.5.3 What is a safety stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.5.4 What is safeguarding? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3.2 DANGER - Make sure that the main power has been switched off! . . . . . . . . . . . . . . . . . . . . . . . 28
1.3.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3.4 CAUTION - Never stand on or use the cabinet as a ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3.5 CAUTION - Make sure that there are no loose screws or turnings inside the computer unit
DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.3.6 CAUTION - Close the cabinet door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3.7 CAUTION - Hot components in controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2 Installation and Commissioning, IRC5 35

2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2 Installation Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.3 Transporting and handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.3.1 Lifting the controller modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.3.2 Unpacking, IRC5 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4 On-site Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4.1 Required installation space, IRC5 Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.4.2 Bolting down the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.4.3 Transportation screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.4.4 Mounting the FlexPendant holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.5.1 Connectors on controller, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.5.2 Connecting a FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.5.3 Connecting a PC to the service port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.5.4 Connection to serial channel connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.5.5 Connecting power supply to the Single Cabinet Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.5.6 Connecting power supply to the Dual Cabinet Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.5.7 Connecting the communication cabling for the Dual Cabinet Controller . . . . . . . . . . . . . . . . . . . 63
2.5.8 Fitting the connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.5.9 Connecting the manipulator to the IRC5 controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.5.10 The MOTORS ON/MOTORS OFF circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.5.11 Connection of external safety relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.5.12 Connection to MOTORS ON/MOTORS OFF contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.5.13 Connection of Drive Module Disconnect, by limit switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.5.14 Connection of servo disconnect, by servo power switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3HAC021313-001 Revision: K 3
Table of Contents
2.5.15 Connecting a Limit switch override push button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

2.6 Drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.6.1 Drive functions, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.6.2 Configuration of the drive system, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.7 Memory functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.7.1 Memory functions, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.7.2 Connecting a USB memory to the computer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.8 I/O system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.8.1 Definition of I/O units, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.9 Installation of add-ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.9.1 Installation of additional Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.9.2 Installation of external operator's panel, IRC5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.9.3 Installation of Drive system parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.9.4 Installation of I/O, Gateways and encoder interface units, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . 113
2.9.5 Installation of PMC-card for Force Control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.9.6 Installation of extra mass memory in computer unit DSQC623 . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.9.7 Installation of Euromap and SPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.9.8 Upgrading and installation of 2X Euromap interface (Option 671-4) . . . . . . . . . . . . . . . . . . . . . 131
2.9.9 Installation of cooling fan harness axis 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.9.10 Installation of Hot plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.9.11 Installing the EPS board DSQC 646 for Electronic Position Switches . . . . . . . . . . . . . . . . . . . 152
2.9.12 Installing the SafeMove board DSQC 647. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.9.13 Installation of Remote Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3 Maintenance activities, controller IRC5 169

3.1 Maintenance schedule, controller IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.2 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.2.1 Inspection of the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.3 Changing/replacing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.3.1 Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.3.2 Replacement of moist dust filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.4 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.4.1 Cleaning of the IRC5 controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.4.2 Cleaning moist dust filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.4.3 Cleaning the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4 Repair activities, controller IRC5 183

4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.2 Replacement of panel board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.3 Replacement of power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.3.1 Replacement of control power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.3.2 Replacement of power distribution board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
4.3.3 Replacement of customer I/O power supply, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.3.4 Replacement of customer I/O power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.3.5 Replacement of drive system power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.3.6 Replacement of system power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4.4 Replacement of Flange disconnect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.5 Replacement of I/O units and Gateways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4.6 Replacement of backup energy bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4.7 Replacement of control system fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.8 Replacement of heat exchange unit and fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.9 Replacement of computer unit DSQC623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4.10 Replacement of computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
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4.11 Replacement of motherboard in computer unit DSQC623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

4.12 Replacement of motherboard in computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
4.13 Replacement of DDR SDRAM memory on motherboard in computer unit DSQC639 . . . . . . . . . . . 240
4.14 Replacement of PCI cards in the computer unit DSQC623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
4.15 Replacement of PCI boards in the computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.16 Replacement of fieldbus adapter in the computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
4.17 Replacement of fan in computer unit DSQC623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
4.18 Replacement of fan in computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
4.19 Replacement of hard disk or IDE Flash module and cable in computer unit DSQC623 . . . . . . . . . . 268
4.20 Replacement of Compact Flash memory in computer unit DSQC639 . . . . . . . . . . . . . . . . . . . . . . . . 272
4.21 Replacement of computer power supply in computer unit DSQC623 . . . . . . . . . . . . . . . . . . . . . . . . . 275
4.22 Replacement of servo drive units, rectifierand capacitorunit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
4.23 Replacement of Axis computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
4.24 Replacement of EPS board DSQC 646 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.25 Replacement of SafeMove board DSQC 647. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
4.26 Replacement of Remote Service box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
4.27 Replacement of Contactor Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
4.28 Replacement of drive system fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
4.29 Replacement of transformer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
4.30 Replacement of brake resistor bleeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
5 Reference information, IRC5 313

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
5.2 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
5.3 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
5.4 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
5.5 Standard toolkit, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
5.6 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
5.7 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
6 Spare Parts 321

6.1 Controller parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
6.1.1 Single Cabinet Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
6.2 Manipulator cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
6.2.1 Manipulator variants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
6.2.2 Manipulator cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

6.2.3 Position switch cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
6.2.4 Fan cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
6.2.5 CP/CS Harness IRB 6400RF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
6.2.6 CP/CS Harness IRB 6600, 7600, 660, 6620 and 6640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
6.2.7 Customer signal, CS/CP and CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
6.2.8 Customer power-signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
6.2.9 External axis cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
7 Circuit Diagram 341

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Index 343
6
Table of Contents
3HAC021313-001 Revision: K
Overview
Overview
About this manual

This manual contains instructions for
• installing the controller, mechanically as well as electrically
• maintenance of the controller
• mechanical and electrical repair of the controller.
Usage
This manual should be used during
• installation, from lifting the controller cabinet to its work site and securing it to the
foundation to making it ready for operation
• maintenance work
• repair work.
Who should read this manual?

This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
A maintenance/repair/ installation craftsman working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and electrical
installation/repair/maintenance work.
References
Reference Document ID
Product manual - IRC5 3HAC021313-001

Emergency safety information 3HAC027098-001
Operating manual - IRC5 with FlexPendant 3HAC16590-1
Operating manual - RobotStudio 3HAC032104-001
Operating manual - Getting started, IRC5 and RobotStudio 3HAC027097-001
Operating manual - Trouble shooting 3HAC020738-001
Technical reference manual - System parameters 3HAC17076-1
Application manual - MultiMove 3HAC021272-001
Revisions
Revision Description
- First edition
Continues on next page

Overview
Continued
D Updates made with the new computer unit DSQC 639 in
sections:
• Safety instructions
• Connecting a PC to the service port
• Connection to serial channel connector
• Memory functions
• Connecting a USB memory to the computer unit
• Installation of external operator’s panel, IRC5
New sections added for the new computer unit DSQC 639:
• Replacement of computer unit DSQC 639
• Replacement of motherboard in computer unit DSQC
639
• Replacements of PCI boards in computer unit DSQC 639
• Replacement of fan in computer unit DSQC 639
• Replacement of Compact Flash memory in computer
unit DSQC639
• Replacement of DDR SDRAM memory on motherboard
in computer unit DSQC 639
Minor corrections made in section Installation of Euromap.
Installation of Hot plug button is described in the new section

Installation of Hot plug.
New Backup energy bank unit is included in section

Repacement of backup energy bank.
New DeviceNet Master/Slave boards are included in sections:

• Definition of I/O units, IRC5
• Replacement of I/O units and gateways

Updates made with 6400RF in sections:
• Configuration of the drive system, IRC5
• Manipulator cables
Circuit diagram is updated to revision 6.

E New option Flange disconnect is described in the new section
Replacement of Flange disconnect.
New safety section Close the cabinet door added.
New section Connecting the communication cabeling to the

Dual Cabinet Controller added.
Minor corrections made.

Overview
Continued
F New option Electronic Position Switches is described in the new
section Installing the EPS board for Electronic Position Switches
and section Replacement of EPS board.
New option Dust filter is described in the new section

Replacement of dust filter and Cleaning dust filter.
New option EtherNet/IP Fieldbus Adapter is described in the

new section Replacement of fieldbus adapter in the computer
unit DSQC 639.
New power supplies are described in the new sections

Replacement of power distribution board, Replacement of
customer I/O power supply and Replacement of system power
supply.
Circuit diagram for option EuroMap and SPI added.

G New option PROFIBUS Fieldbus Adapter is added to section
Replacement of fieldbus adapter in the computer unit DSQC
639.

H Corrections in section Spare Parts, Manipulator cables.
Circuit diagram is updated to revision 1.
J New option SafeMove is described in the new section Installing
the SafeMove board DSQC 647 and section Replacement of
SafeMove board DSQC 647.
Changes made in section Maintenance schedule, controller

IRC5. Replacement of fans every third year is withdrawn and
inspection interval is changed from once a year to twice a year.
Changes made in section Installation of Euromap.
Updates made with IRB 360 in sections:

• Configuration of the drive system, IRC5
• Manipulator cables
New option Remote Service is described in the new section

Installation of Remote Service and section Replacement of
Remote Service box.
Circuit diagram updated to revision 2.

Overview
Continued
K New option PROFINET Fieldbus Adapter is added to section
Replacement of fieldbus adapter in the computer unit DSQC
639.
New option PROFINET master/slave is added to section
Replacements of PCI boards in computer unit DSQC 639.
New option Euromap II upgrade option 671-4 added in section
Installation of add-ons.
Filter time for safety stop AS/GS/SS is added in section The
MOTORS ON/MOTORS OFF circuit on page 68.
Instructions how to replace the brake resistor bleeder in the Dual

Cabinet Controller, Drive Module is added to section
Repacement of brake resistor bleeder.
Product documentation, M2004
General
The robot documentation is 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.
Product manuals
All hardware, robots and controllers, will be delivered with a Product manual that contains:
• Safety information
• Installation and commissioning (descriptions of mechanical installation, electrical
connections)
• 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)
• 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
Technical reference 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 Instructions, Functions and Data types: Description and syntax for all
RAPID instructions, functions and data types.
• System parameters: Description of system parameters and configuration workflows.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful)
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, CD with PC software)
• How to use the application
• Examples of how to use the application

Continued
Operating manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
that is production cell operators, programmers and trouble shooters. The group of manuals
includes:
• Emergency safety information
• General safety information
• Getting started, IRC5
• IRC5 with FlexPendant
• RobotStudio
• Introduction to RAPID
• Trouble shooting, for the controller and robot
1 Safety
1.1. Introduction
1 Safety
1.1. Introduction
Overview
The safety information in this manual is divided in two categories:
• general safety aspects, important to attend to before performing any service or
installation work on the controller. These are applicable for all service work and are
found in section General safety information.
• specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in section Safety related instructions on
page 26.
1 Safety
1.2.1. Introduction
1.2 General safety information
1.2.1. Introduction
Definitions
This section details general safety information for personnel performing installation, repair
and maintenance work.
Sections
The general safety information is divided into the following sections.
Contents Containing
1. General information • safety, service
• limitation of liability
• related information
2. Safety risks (lists dangers relevant • safety risks during installation or service
when working with the controller. • risks associated with live electrical parts
The dangers are split into different
categories).
3. Safety actions (details actions • fire extinguishing
which may be taken to remedy or • safe use of the FlexPendant
avoid dangers).
1 Safety
1.2.2.1. Safety in the robot system
1.2.2. General Information
1.2.2.1. Safety in the robot system
Validity and responsibility

The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system are designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the
industrial robot, described in the applicable documents, for example:
• Operating Manual - IRC5 with FlexPendant (M2004)
• Product Manual
Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can
interact with other machines and peripheral equipment. This means that control signals can
act on safety signals received from the peripheral equipment as well as from the robot.
Limitation of liability
Any information given in this manual regarding safety, must not be construed as a warranty
by ABB that the industrial robot will not cause injury or damage even if all safety instructions
are complied with.
Related information
Type of information Detailed in document Section

Installation of safety Product manual for the robot Installation and commissioning
devices
Changing operating Operating manual - IRC5 with Operating modes
modes FlexPendant
(RobotWare 5.0)
Restricting the working Product manual for the robot Installation and commissioning
space
1 Safety
1.2.3.1. Risks associated with live electric parts
1.2.3. Safety risks
1.2.3.1. Risks associated with live electric parts
Voltage related risks, general

• Although troubleshooting may, on occasion, need to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
• The mains supply to the robot must be connected in such a way that it can be turned
off outside the robot’s working space.
Voltage related risks, IRC5 controller

A danger of high voltage is associated with, for example, the following parts:
• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the
controller.
• Units such as I/O modules, can be supplied with power from an external source.
• The mains supply/mains switch
• The transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
• The drive unit (700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (230 VAC)
• The power supply unit for additional tools, or special power supply units for the
machining process.
• The external voltage connected to the controller remains live even when the robot is
disconnected from the mains.
• Additional connections.
Voltage related risks, tools, material handling devices, etc

Tools, material handling devices, etc., may be live even if the robot system is in the
OFFposition. Power supply cables which are in motion during the working process may be
damaged.
1 Safety
1.2.4.1. Fire extinguishing
1.2.4. Safety actions
1.2.4.1. Fire extinguishing
NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot system (robot
or controller)!
1 Safety
1.2.5.1. Overview of robot stopping functions
1.2.5. Safety stops
Overview
Stops are categorized/classified by standards IEC 60204-1:2005 and ISO 10218-1:2006.
There are several different robot stopping functions in the robot system.
• Hardware stops connected to the run chain.
• Manual stops.
• Stop with system input signals.
• Stop with RAPID instructions.
• System failure stops.
Stop modes
Stops can be in uncontrolled or controlled mode. The stop mode is configured with system
parameters, see Soft stops on page 19.
Uncontrolled stop This is related to stop category 0 as described in IEC 60204-

1:2005, which means that power is removed immediately from
the drive units, by releasing the run chain through the software
enable signal, and the brakes are activated. Also the servo
motors are used for the braking, by reversing to "generator" and
ramping down the generated power in a controlled way.
In this way, both the brakes and the motors are used to stop the
robot, giving the shortest possible stop time and stop distance.
However it also means that the robot mechanics will be highly
stressed and the robot will leave the programmed path and stop
at an uncontrolled position.
Controlled stop This is related to stop category 1 as described in IEC 60204-
1:2005.It means that the power will be connected to the drive
units for about 1 second, by a hardware delay, and the
movement will be put to a full stop using the servo motors before
the power is removed and the brakes are activated.
This way the robot will stop at a controlled point on or very close
to the programmed path. The controlled stop is also called "soft"
because it will be more soft for the mechanics, but note, it is the
same as a QuickStop when initiated via a system input, see
below.
Hardware stops connected to the run chain

There are several hardware stops available. All these stops are of safety category 3 as
described in EN 954-1 or EN 13849-1, that is double channel initiated stop.
Stop connections: Description:

Emergency stop Disconnects drive power in all operating modes.
Automatic mode stop Disconnects drive power in automatic operating mode. To be
used as "Protective stop" in auto.
Also called "Safety stop".
In manual mode this input connection will be inactive.

1 Safety
Continued
Stop connections: Description:

General stop Disconnects drive power in all operating modes. To be used as
"Protective stop" in all operating modes.
Superior stop Disconnects drive power in all operating modes. To be used as
"Protective stop" in all operating modes.
Intended for external equipments.
Soft stops
The stop mode for hardware stops is configured with system parameters, one parameter for
each stop. Each of these parameters can have the value TRUE or FALSE (true or false). If
TRUE the stop will be controlled or soft, that is category 1, if FALSE it will be uncontrolled,
that is category 0, (see exception below). Default values are TRUE for SoftAS, SoftGS, and
SoftSS, and FALSE for SoftES. The parameters are of the type Safety Run Chain in the topic
Controller. The following descriptions apply if the values are set to TRUE.
Soft Stop: Description:

SoftES Soft emergency stop is activated by pressing the emergency
stop push button on the FlexPendant or the control module.
SoftES is only used in auto. In manual mode, emergency stop
will be a category 0 stop regardless if the value is TRUE or
FALSE.
SoftAS Soft automatic mode stop is intended for automatic mode during
normal program execution. This stop is activated by safety
devices such as light curtains, light beams, or sensitive mats.
SoftGS Soft general stop is activated by safety devices such as light
curtains, light beams, or sensitive mats.
SoftSS Soft superior stop has the same function as a general stop but
is intended for externally connected safety devices.
Manual stops
A manual stop is initiated by a person. It can be a controlled or an uncontrolled stop

depending on how the stop is initiated.
Stop mode: Manual stop: Description:

Controlled Stop button on FlexPendant This will stop program execution and
or cause an immediate stop of robot
Release of Hold-to-run button movements in all tasks.
The robots will stop in a controlled way
and on the path with no deviation. This
is called "normal progam stop".
Uncontrolled Release of enabling device This will stop program execution and
or stop all program movements.
Switching operating mode key

1 Safety
Continued
Stop with system input signals

In addition to the hardware stops as described above, it is also possible to define system input
signals, which will give an immediate or delayed stop of different modes for all tasks and
robots, when activated. Such signals are defined as system parameters of the type System
Input in the topic I/O and for the following stop modes.
Stop mode: Description:

Stop Stops the RAPID program execution. All robot movements will
be stopped on the path with no deviation. A program cannot be
started when this signal is high. This stop is similar to a normal
program stop using stop button on the FlexPendant.
QuickStop Stops the RAPID program execution quickly, like a controlled
category 1 emergency/safety stop . This stop is performed by
ramping down motion as fast as possible using optimum motor
performance. The different axes are still coordinated to trying to
keep the robot on path even if the robot may slide off with some
millimeter. Note, this kind of stop is more stressing for the
mechanics than normal stop or SoftStop.
SoftStop Stops the RAPID program execution much like an ordinary
program stop, but slightly faster. The stop is performed by
ramping down motion in a controlled and coordinated way, to
keep the robot on the programmed path with minor deviation.
This kind of stop is more "soft" to the mechanics than the
QuickStop.
Stop at End of Cycle Stops the RAPID program when the complete program is
executed, that means when the last instruction in the main
routine has been completed.
Stop at End of Program Stops program execution after the current instruction is
completed.
All of these stops are performed without using the brakes, and the power is never
disconnected. The program execution can be continued directly, for example by activating a
start signal.
NOTE!
Note, these stops shall not be used as safety stops, as they are not fulfilling safety category 3. © Copyright 2004-2008 ABB. All rights reserved.
Stop with RAPID instructions

There are several RAPID instructions available that stops the robot.
Instruction: Description: Arguments:

SystemStopAction Stops all robots in all tasks imme- \Stop - similar to a normal program
diately. stop with stop button.
\StopBlock - as above, but to
restart the PP has to be moved.
\Halt - this is like a category 0 stop,
i.e. it will result in motors off state,
stop of program execution and
robot movements in all motion
tasks. The Motors on button must
be pressed before the program
execution can be restarted.

1 Safety
Continued
Instruction: Description: Arguments:

Stop The current move instruction will \NoRegain - the robot will not
be finished before the robot stops. return to the stop point when
A restart will continue the program restarted, e.g. after having been
execution. jogged away.
\AllMoveTasks - all robots will be
stopped
StopMove The current move instruction will \Quick - the stop will be a soft stop
be stopped immediately as a on path, as described above for
normal program stop but the system input SoftStop, otherwise
program execution will continue similar to a normal program stop.
with the next instruction. This is \AllMotionTasks - all robots will be
often used in for example trap stopped
routines.
BREAK The current move instruction and
the program execution will be
stopped immediately as a normal
program stop. A restart will
continue the program execution.
EXIT The current move instruction and
the program execution will be
stopped immediately as a normal
program stop. After stop the
Program Pointer has to be reset to
Main.
EXITCYCLE The current move instruction and
program execution will be stopped
immediately. The Program Pointer
will be reset to Main and if running
mode is continuous, the program
will be restarted.
SearchX Search instructions can be \Stop - the robot will stop as fast as
programmed with arguments to possible. This stop is performed
stop the robot movement close to by ramping down motion in each
the point where a search hit was motor separate from each other,
noticed. The program execution and as fast as possible. Since it
will continue with the next instruc- will be without any coordination,
tion. the robot may slide off path fairly
much. This is also called StiffStop.
\PStop - the robot will stop like
after a normal program stop.
\SStop - the robot will stop on path
but quicker than a normal program
stop. This is similar to a system
input SoftStop.
RAPID instructions are described in Technical reference manual - RAPID Instructions,

Functions and Data types.
System failure stops
Type of stop: Description:

SysFail At system failure raising a SysFail error the robot will stop imme-
diately, with brakes being activated.
This is an uncontrolled stop category 0.

1 Safety
Continued
Type of stop: Description:

Power fail At power failure the robot will stop immediately, with brakes
being activated.
Stop at collision When a collision is detected the robot will stop immediately, with
power disconnected from the drive units and the brakes
activated.
After full stop the power is reconnected and the residual forces
are relieved by moving the robot in the reversed direction a
short distance back to its path. Then the program execution will
stop with an error message.
The robot remains in the state Motors on so that program
execution can be resumed after the collision error message has
been acknowledged.
1 Safety
1.2.5.2. What is an emergency stop?
1.2.5.2. What is an emergency stop?
Definition of emergency stop

An emergency stop is a state that overrides any other robot control, disconnects drive power
from the robot motors, stops all moving parts, and disconnects power from any potentially
dangerous functions controlled by the robot system.
An emergency stop state means that all power is disconnected from the robot except for the
manual brake release circuits. You must perform a recovery procedure in order to return to
normal operation.
The robot system can be configured so that the emergency stop results in either:
• An uncontrolled stop, immediately stopping the robot actions by disconnecting power
from the motors.
• A controlled stop, stopping the robot actions with power available to the motors so that
the robot path can be maintained. When completed, power is disconnected.
The default setting is uncontrolled stop. However, controlled stops are preferred since they
minimize extra, unnecessary wear on the robot and the actions needed to return the robot
system back to production. Please consult your plant or cell documentation to see how your
robot system is configured.
NOTE!
The emergency stop function may only be used for the purpose and under the conditions for
which it is intended.
NOTE!
The emergency stop function is intended for immediately stopping equipment in the event of
an emergency.
NOTE!
Emergency stop should not be used for normal program stops as this causes extra,
unnecessary wear on the robot. How to perform normal program stops, see Stopping
programs.
Classification of stops
The safety standards that regulates automation and robot equipment defines categories in
which each type of stop applies:
If the stop is... ... then it is classified as...
uncontrolled category 0 (zero)
controlled category 1
Emergency stop devices

In a robot system there are several emergency stop devices that can be operated in order to
achieve an emergency stop. There are emergency stop buttons available on the FlexPendant
and on the controller cabinet (on the Control Module on a Dual Cabinet Controller). There
can also be other types of emergency stops on your robot, consult your plant or cell
documentation to see how your robot system is configured.
1 Safety
1.2.5.3. What is a safety stop?
1.2.5.3. What is a safety stop?
Definition of safety stops

A safety stop means that only the power to the robot motors is disconnected. There is no
recovery procedure. You need only to restore motor power to recover from a safety stop.
Safety stop is also called protective stop.
The robot system can be configured so that the stop results in either:
• An uncontrolled stop, immediately stopping the robot actions by disconnecting power
from the motors.
• A controlled stop, stopping the robot actions with power available to the motors so that
the robot path can be maintained. When completed, power is disconnected.
The default setting is controlled stop.
Controlled stops are preferred since they minimize extra, unnecessary wear on the robot and
the actions needed to return the robot system back to production. Please consult your plant or
cell documentation to see how your robot system is configured.
NOTE!
The safety stop function may only be used for the purpose and under the conditions for which
it is intended.
NOTE!
Safety stop should not be used for normal program stops as this causes extra, unnecessary
wear on the robot. How to perform normal program stops, see Stopping programs.
Classification of stops
The safety standards that regulates automation and robot equipment defines categories in
which each type of stop applies:
If the stop is... ... then it is classified as...
uncontrolled category 0 (zero)

controlled category 1
Type of safety stops

Safety stops are activated through special signal inputs to the controller, see Product manual
- IRC5. The inputs are intended for safety devices such as cell doors, light curtains, or light
beams.
Safety stop: Description:

Automatic mode stop (AS) Disconnects drive power in automatic mode.
In manual mode this input is inactive.
General stop (GS) Disconnects drive power in all operating modes.
Superior stop (SS) Disconnects drive power in all operating modes.
Intended for external equipment.
NOTE!
Use normal program stop for all other type of stops.
1 Safety
1.2.5.4. What is safeguarding?
1.2.5.4. What is safeguarding?
Definition
Safeguarding are safety measures consisting of the use of safeguards to protect persons from
hazards which cannot reasonably be removed or sufficiently eliminated by design.
A safeguard prevents hazardous situations by stopping the robot in a controlled manner when
a certain safeguarding mechanism such as a light curtain is activated.
The safety stops described in What is a safety stop? on page 24, should be used for
safeguarding.
NOTE!
The safeguarding function may only be used for the purpose and under the conditions for
which it is intended.
NOTE!
The safeguarding should not be used for normal program stops as this causes extra,
unnecessary wear on the robot. How to perform normal program stops, see Stopping
programs.
Safeguarded space
The safeguarded space is the space guarded by the guards. For example, a robot cell is
safeguarded by the cell door and its interlocking device.
Interlocking devices
Each present guard has an interlocking device which, when activated stops the robot. The
robot cell door has an interlock that stops the robot when the door is opened. The only way
to resume operation is to close the door.
Safeguarding mechanisms
A safeguarding mechanism consists of a number of guards connected in series. When a guard
is activated, the chain is broken and the machine operation is stopped regardless of the state
of the guards in the rest of the chain.
NOTE!
Use normal program stop for all other type of stops.
1 Safety
1.3.1. Safety signals, general
1.3 Safety related instructions
General
This section specifies all dangers that may arise from performing the work detailed in the
manual. Each danger is detailed in its own section consisting of:
• A caption specifying the danger level (DANGER, WARNING or CAUTION) and the
type of danger.
• A brief description of what will happen if the operator/service personnel do not
eliminate the danger.
• An instruction of how to eliminate the danger to facilitate performing the activity at
hand.
Danger levels
The table below defines the captions specifying the danger levels used throughout this
manual.
Symbol Designation Signification

DANGER Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
danger impact, fall from height etc.
WARNING Warns that an accident may occur if the instructions
are not followed, that can lead to serious injury,
possibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk of
warning crushing, impact, fall from height etc.
ELECTRICAL The electrocution or electrical shock symbol
SHOCK indicates electrical hazards which could result in
severe personal injury or death.
Electrical shock
CAUTION Warns that an accident may occur if the instructions

are not followed, that can result in injury and/or
damage to the product. It also applies to warnings of
risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping,
impact, fall from height etc. Furthermore, it applies to
caution warnings that include function requirements when
fitting and removing equipment, where there is a risk
of damaging the product or causing a breakdown.

1 Safety
Continued
Symbol Designation Signification

ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates
DISCHARGE (ESD) electrostatic hazards which could result in severe
damage to the product.
Electrostatic discharge
(ESD)
NOTE Note symbols alert you to important facts and

conditions.
Note
TIP Tip symbols direct you to specific instructions, where

to find additional information or how to perform a
certain operation in an easier way.
Tip
1 Safety
1.3.2. DANGER - Make sure that the main power has been switched off!
1.3.2. DANGER - Make sure that the main power has been switched off!
Description
Working with high voltage is potentially lethal. Persons subjected to high voltage may suffer
cardiac arrest, burn injuries, or other severe injuries. To avoid these dangers, do not proceed
working before eliminating the danger as detailed below.
Elimination, Single Cabinet Controller
Action Note/illustration
1. Switch off the main switch on the controller
cabinet.
xx0600002782
A: Main switch
Elimination, Dual Cabinet Controller

1. Switch off the main switch on the Control
Module.
xx0600002783
A: Main switch, Control Module

2. Switch off the main switch on the Drive K: Main switch, Drive Module (see illustra-
Module. tion above)
1 Safety
1.3.3. WARNING - The unit is sensitive to ESD!
1.3.3. WARNING - The unit is sensitive to ESD!
Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at
different potentials, either through direct contact or through an induced electrical field. When
handling parts or their containers, personnel not grounded may potentially transfer high static
charges. This discharge may destroy sensitive electronics.
Elimination
Action Note
1. Use a wrist strap Wrist straps must be tested frequently to ensure
that they are not damaged and are operating
correctly.
2. Use an ESD protective floor mat. The mat must be grounded through a current-
limiting resistor.
3. Use a dissipative table mat. The mat should provide a controlled discharge of
static voltages and must be grounded.
Location of wrist strap button

The wrist strap button is located in the right corner as shown in the illustration below.
xx0500002171
A Wrist strap button
1 Safety
1.3.4. CAUTION - Never stand on or use the cabinet as a ladder
1.3.4. CAUTION - Never stand on or use the cabinet as a ladder
Description
To avoid personal injury or damaging the product, it is never allowed to stand on the single
cabinet or the modules of the dual cabinet. Nor is it allowed to use the single cabinet or the
modules of the dual cabinet as a ladder.
1 Safety
1.3.5. CAUTION - Make sure that there are no loose screws or turnings inside the computer unit DSQC639
1.3.5. CAUTION - Make sure that there are no loose screws or turnings inside the
computer unit DSQC639
Description
To avoid damaging the product, do not proceed working before checking that there are no
loose screws, turnings or other parts inside the computer unit after that work has been
performed inside the Controller Cabinet.
1 Safety
1.3.6. CAUTION - Close the cabinet door
1.3.6. CAUTION - Close the cabinet door
Description
The cabinet door must be closed properly when the robot system is in production. If a door is
not properly closed, the cabinet does not comply with the protection class IP54. The shield
for Electro Magnetic Compatibility is also affected if the door is not properly closed.
1 Safety
1.3.7. CAUTION - Hot components in controller
Description
Units and heat sinks are HOT after running the robot!
Touching the units and heat sinks may result in burns!
With higher environment temperature more surfaces on the controller get HOT and may
result in burns.
1 Safety
2 Installation and Commissioning, IRC5
2.1. Overview

2.1. Overview
General
The ABB IRC5 controller is available in two basic configurations: Single Cabinet Controller
and Dual Cabinet Controller.
xx0600002929
A Dual Cabinet (Control Module)

B Dual Cabinet (Drive Module)
C Single Cabinet
The Single Cabinet Controller has all components in one single cabinet and the Dual divides
the components into two modules: Control Module and Drive Module.
The Single Cabinet Controller is regarded as the standard configuration and therefor the
illustration in the procedures detailed in this manual are based on the Single Cabinet
Controller.
If the procedure in general is the same, it is mentioned in each procedure where the part is
located in the Dual Cabinet configuration. If there are significant differences, both cabinet
configurations are shown.
NOTE!
When replacing a unit in the controller, report to ABB:
• the serial number
• articel number
• revision
of both the replaced unit and the replacement unit.
This is particularly important for the safety equipment to maintain the safety integrety of the
installation.
2.2. Installation Activities
2.2. Installation Activities
Preconditions
The following section details the main steps on how to unload, transport, install and connect
the IRC5 Controller modules.
Procedure
Action Info/Illustration
1. Unpack the delivered IRC5 Controller. How to lift,unpack and transport the IRC5
controller is detailed in section Lifting the
controller modules on page
37andUnpacking, IRC5 Controller on page
38
2. Install the IRC5 Controller. How to install the IRC5 controller is
detailed in sectionBolting down the
controller on page 41
3. Connect the manipulator to IRC5 How to connect the manipulator to IRC5
Controller. controller is detailed in section Connecting
the manipulator to the IRC5 controller on
page 67..
4. Connect power supply to the IRC5 How to connect power supply is detailed in
Controller. sections,
Connecting power supply to the Single
Cabinet Controller on page 58.
Connecting power supply to the Dual
5. Connect the FlexPendant to the IRC5 How to connect the FlexPendant is
Controller. detailed in section Connecting a
FlexPendant on page 51.
6. Miscellaneous connections. How to connect MOTORS ON/MOTORS
OFF circuits is detailed in section The
MOTORS ON/MOTORS OFF circuit on
page 68.

How to connect to an external safety relay
is detailed in Connection of external safety
relay on page 73.
How to connect buses e.g DeviceNet, is
detailed in the Application manual for the
bus respectively.
How to connect I/O units to the IRC5
controller is detailed in the Application
manual for the I/O unit respectively.
How to connect to a network is detailed in
section Connecting a PC to the service
port on page 52.
7. If used, install add-ons. How to install add-ons is detailed in section
Installation of add-ons on page 102
2.3.1. Lifting the controller modules
2.3 Transporting and handling
2.3.1. Lifting the controller modules
Lifting device
Use the two lifting eyes or a fork lift when lifting the IRC5 controller, as shown below.
The figure below shows the maximum angle between the lifting straps when lifting the
controller. The weight of the controller modules are detailed in section Unpacking, IRC5
Controller on page 38
xx0200000076
2.3.2. Unpacking, IRC5 Controller
General
Before unpacking and installing the robot system, read the safety regulations and other
instructions very carefully. These are found in Chapter Safety.
The installation must be done by qualified installation personnel and should conform to all
national and local codes.
When unpacking the controller, check that it was not damaged during transport.
NOTE!
If the IRC5 Controller is going to be stored before unpacking and installation, read the
following information regarding storage conditions.
Storage conditions
The table below shows the recommended storage conditions for the IRC5 Controller:
Parameter Value
Min. ambient temperature -25 C
Max. ambient temperature +55 C
Max. ambient temperature (option) +70 C
Max. ambient humidity Max. 95% at constant temperature
Weight controller
The table below shows the weight for the IRC5 Controller:
Controller Weight
Single Cabinet Controller max. 150 kg
Dual Cabinet Controller max. 180 kg
• Control Module 50 kg
• Drive Module 100-130 kg

Operating conditions
The table below shows the allowed operating conditions for the IRC5 Controller:
Parameter Value
Min. ambient temperature +5 C
Max. ambient temperature +45 C
Max. ambient temperature (option) +52 C
Max. ambient humidity Max. 95%
Protection class
The table below shows the protection classes for the IRC5 Controller and FlexPendant:
Equipment Protection class

IRC5 Single or Dual Cabinet Controller IP54

Continued
Equipment Protection class

FlexPendant IP54
2.4.1. Required installation space, IRC5 Controller
2.4 On-site Installation
2.4.1. Required installation space, IRC5 Controller
Dimensions
The figure below shows the required installation space for the IRC5 controller, the illustration
shows a Single Cabinet Controller. The measures are the same for the Dual Cabinet
Controller.
xx0500001848
NOTE! The free space on the right hand side of the controller is required to allow opening
the door a full 180° and to access the optional moist dust filter.
NOTE! The air distance 200 mm on the backside of the controller is required to allow © Copyright 2004-2008 ABB. All rights reserved.
inspection and replacement of the optional moist dust filter and ensure proper cooling.
NOTE! Do not place customer cables over the moist dust filters on the backside of the
controller. Makes difficult to inspect and replace the moist dust filters.
2.4.2. Bolting down the controller
2.4.2. Bolting down the controller
Bolt pattern, Single Cabinet Controller and Dual Cabinet Controller Design 2006
The figure below shows the bolt pattern for the Single Cabinet Controller:
xx0500001853
Bolt pattern, Dual Cabinet Controller Design 2004

The figures below shows the bolt pattern for the Control Module and the Drive Module.
45
xx0200000075
2.4.3. Transportation screws
2.4.3. Transportation screws
General
During transportation the kick cover is secured with two screws. The two screws must be
removed before removal of the plate and connection of cables. The screws are located as
shown in the illustration below.
xx0500002038
2.4.4. Mounting the FlexPendant holder
Location
The placement of the FlexPendant holder is shown in the illustration below.
xx0500002542
A FlexPendant holder mounted on top of the control cabinet.

B FlexPendant holder mounted on the control cabinet door.
NOTE!
In order to avoid drop of the FlexPendant from high levels, the location of the FlexPendant
holder on top of the control cabinet is recommended only with one single cabinet. Otherwise
according to location on the control cabinet door.
Required equipment
Equipment Art.no Note

Standard tool kit The contents are defined in

section, Standard Toolkit.
FlexPendant holder 3HAC12678-1

Continued
Procedure - On top of the control cabinet

The following procedure details how to mount the FlexPendant holder on top of the control
cabinet.
1. Remove the protective liner from the tape.
xx0500002546
2. Press the mounting plate with FlexPendant

holder against the top of the control cabinet.
NOTE!
The surface must be clean and dry.
3. Mount the cable bracket holder on the side of
the cabinet.
Use one of the excisting M8 screws.
xx0700000240
• A: Cable bracket holder

4. Mount the cable bracket on the cable bracket
holder using enclosed Fastite screws (4 pcs).
xx0700000241
• A: Cable bracket

Continued
Procedure - On the control cabinet door

The following procedure details how to mount the FlexPendant holder on the control cabinet
door.
Action Note/Illustration
1. At assembly of FlexPendant holder on the
mounting plate start with fasten the
Fastite screws (2 pcs) to the mounting A
plate.
xx0800000048
• A: Fastite screw (2 pcs)

2. Bend the two flanges on the mounting
plate to match the upper shape of the
door.
xx0700000242
• A: Flange
3. Mount the FlexPendant holder and cable
bracket to the mounting plate with the
enclosed Fastite screws (6 pcs). A
B
xx0700000244
• A: Cable bracket
• B: FlexPendant holder
4. Remove the protective liner from the tape
on the mounting plate.
Continued
5. Press the mounting plate against the
control cabinet door.
NOTE!
The surface must be clean and dry.
xx0700000243
2.5.1. Connectors on controller, IRC5
2.5 Connections
General
The following section describes the connectors on respective front panels on the IRC5
controller. These are described below.
Single Cabinet Controller

The following details the connection interface on the Single Cabinet Controller.
Small robots
The following details the connection interface for small robots.
xx0500001852
Description
A XP.0 Mains connection
B XS.1 Robot power connection
C XS.7 Additional axes power connection
D XS.58 Position switches
E XS.8 Position switches
F XS.13/XS.5 Customer power/signals external connection
G XS.10 Customer options

H XS.11 Customer options
J XS.12 Customer options
K X3 Customer safety signals
L XS.28 Network connection
M XS.41 Additional axes SMB connection
N XS.2 Robot SMB connection

Continued
Large robots
The following details the connection interface for large robots.
Old connection interface:
xx0500002044
New connection interface:
xx0700000425
Description
A XP.0 Mains connection
B XS.1 Robot power connection
C XS.7 Additional axes power connection
D XS.58 Position switches
E XS.8 Position switches
F XS.13/XS.5 Customer power/signals external connection © Copyright 2004-2008 ABB. All rights reserved.
G XS.10 Customer options
H XS.11 Customer options
J XS.12 Customer options
K X3 Customer safety signals
L XS.28 Network connection
M XS.41 Additional axes SMB connection
N XS.2 Robot SMB connection

Continued
Dual Cabinet Controller

The following details the connectors on the frontpanel of the Dual Cabinet Controller, that is
the Control Module and the Drive Module.
Control Module
The following details the connectors on the frontpanel of the Control Module.
xx0400000931
Description
A Power connection
B A5.X8: Position switches
C A5.X58: Position switches
D A5.X5: Customer power/signals external connection
E A5.X11: Customer options
F A5.X12: Customer options
G A5.X13: Customer options
H A5.X14: Customer options
J A5.X3: Customer safety signals
K A22.X1: FlexPendant connection
L A5.X28: Network connection

Continued
Drive Module
The following details the connectors on the frontpanel of the Drive Module.
Small robots:
xx0600002931
Large robots:
xx0700000424

Description
A A4.X0: Mains connection to transformer
B A4.XS25: Power to Control Module
C A4.X1: Robot power connection
D A4.X7: External axes power connection
E A4.XX: Customer options
F A4.XX: Customer options
G A4.XX: Customer options
H A4.XX: Customer options
J Communication cabling between Control/Drive Module
K Communication cabling between Control/Drive Module
L A4.XS41: Additional axes SMB connection
M A4.XS2: Robot SMB connection
2.5.2. Connecting a FlexPendant
2.5.2. Connecting a FlexPendant
Location of FlexPendant connector

The FlexPendant connector is located as shown below.
xx0600002782
L FlexPendant connector (A22.X1)

On a Dual Cabinet Controller, the FlexPendant connector is located on the front of the
Control Module.
Connecting a FlexPendant
Action Info
1. Locate the FlexPendant socket connector The controller must be in manual mode. If
on the controller. your system has the option Hot plug, then
you can also disconnect in auto mode. See
section Using the hot plug option.
2. Plug in the FlexPendant cable connector.
3. Screw the connector lock ring firmly by
turning it clockwise.
2.5.3. Connecting a PC to the service port
NOTE!
The service port shall only be used for direct connection to a PC as described in this
procedure. It must not be connected to a LAN (local area network), since it has a DHCP server
that automatically distributes IP addresses to all units connected to the LAN.
Contact your network administrator if you need more information.
NOTE!
Maximum number of connected network clients using robapi are:
• LAN: 3
• Service: 1
• FlexPendant: 1
Total max. number of applications using robapi running on the same pc connected to one
controller has no builtin maximum, however UAS limits the max number of logged on user’s
to 50.
Total max. number of concurrent connected ftp clients are 4.
CAUTION!
When a cable is connected to the service port on the controller front and the service hatch or
the connector cover on the single cabinet are opened, the controller will not comply with the
requirements of protection class IP54.
Ports DSQC623
The illustration below shows the two main ports on the computer unit: the Service Port and
the LAN port. Make sure the LAN (factory network) is not connected to any of the service
ports!
A
B
xx0400001299
A Service port on computer unit (connected to Service port on the Control Module
front through a cable)
B LAN port on computer unit (connects to factory LAN)

Continued
Connections to ports may be done as detailed below:

Connection to/from: Detailed in section:
Connecting the Single Cabinet/Control
Module to the factory LAN.
Connecting a PC to the Single Cabinet/ Proceed as detailed below!
Control Module service port.
Ports DSQC639
The illustration below shows the two main ports on the computer unit: the Service Port and
the LAN port. Make sure the LAN (factory network) is not connected to any of the service
ports!
xx0600002889
A Service port on the computer unit (connected to Service port on the Control
Module front through a cable)
B LAN port on computer unit (connects to factory LAN)
Connections to ports may be done as detailed below.
Connection to/from: Detailed in section:

Connecting the Single Cabinet/Control
Module to the factory LAN.
Connecting a PC to the Single Cabinet/ Proceed as detailed below.
Control Module service port.

Continued
Connecting a PC to the service port
Action Illustration
1. Make sure the network setting on the PC to Refer to the system documentation for
be connected is correct. your PC, depending on the operative
system you are running.
The PC must be set to “Obtain an IP
address automatically” or set as described
in Service PC Information in the Boot
Application.
2. Use the delivered category 5 Ethernet The cable is delivered in the RobotWare
crossover boot cable with RJ45 product box.
connectors.
3. Connect the boot cable to the network port
of your PC.
xx0400000844
• A: network port
The placement of the network port may
vary depending on the PC model.
4. Connect the boot cable to the service port
on the controller.
xx0600002891
• A: Service port
2.5.4. Connection to serial channel connector
Overview
The controller has one serial channel RS232 for permanent use which can be used for
communication point to point with printers, terminals, computers or other equipment.
The following sections detail connection to the serial channel connector (COM1) on the
computer unit.
Location DSQC623
The serial channel connector is placed on a PCI board mounted in the computer unit, as shown
below.
xx0400000883
Description
A Bay for hard disk/IDE flash module
B X1 power supply connector
C PWR (green)
D HDD (yellow
E A32 RCC
F Console
G COM1
H USB 1, 2 computer unit (USB 2 is normally connected to power supply supervision)
J USB 3, 4 computer unit (Not used)
K LAN
L A33 Profibus DP M/S, Interbus M/S (optical fiber), A38 Interbus M/S (copper wire),
A35 DeviceNet, Multimove Ethernet card.

Continued
Location DSQC639
The serial channel connector is placed on the computer unit as shown below.
xx0600002892
Description
A COM1
Required equipment
Equipment Note
RS-232/422 converter DSQC 615
See Computer unit DSQC 639 parts on page
325 for spare part number.
Circuit diagram See Circuit Diagram on page 341

Continued
Conversion of the RS232 channel

The RS232 channel can be converted to RS422 full duplex with an optional adapter (Option
714-1).
The RS422 enables a more reliable point to point communication (differential) over longer
distances, from RS232 = 15m to RS422 = 120m.
Action Info/Illistration
1. Connect the adapter to the serial channel For computer unit DSQC639 a cable is
connector. needed between the serial channel
connector and the adapter.
xx0600003075
• A: cable
• B: adapter
2.5.5. Connecting power supply to the Single Cabinet Controller
General
The following sections details how to connect power supply to the Single Cabinet Controller.
Location
xx0500001869
A Cable gland
Prerequisites
Equipment Note

Power supply cable (3-phase)
External earth fault protection at control cables 3 -15m 30mA
External earth fault protection at control cables >15m 300mA
Standard toolkit The contents are defined in
section Standard toolkit!
Other tools and procedures may be required. See These procedures include
references to these procedures in the step-by-step references to the tools required.
instructions below.
Circuit Diagram See Circuit Diagram on page 341
Connection through a cable gland

The following procedures detail how to connect the mains power to the controller through a
cable gland.
1. Connect power supply from an external Described in section, Prerequisites
earth fault protection.
Continued
2. Fit the cable trough the cable gland and
tighten.
xx0500001870
Parts:
• A: cable gland
• B: rotary switch
• C: cable pipe
• D: grounding point
3. Strip the insulation on the power supply
cable long enough to reach the rotary
switch.
4. Connect the ground cable at the See illustration above. Tightening torque,
grounding point. 4.5Nm.

Continued
5. Route the phase wires through the pipe See illustration above.
up to the rotary switch.
6. Connect the wires as shown in the illus-
tration.
xx0500001882
Connection through a connector

The following procedures detail how to connect the mains power to the controller through a
connector.
NOTE!
To fabricate a cable with connector is described in section Fitting the connector on page 65
1. Connect the power cable from the shop
supply to connector XP0 on the front panel
on the controller.

xx0500001852
Parts:
• A: XP0 Mains power connector
2.5.6. Connecting power supply to the Dual Cabinet Controller
General
The following sections details how to connect power supply to the Dual Cabinet Controller
for both the Control Module and the Drive Module.
Location
xx0400000758
A Harness-230V from Drive Module to Control Module.

B Cable gland for Harness-230V.
To Control Module
Normally the 230 V cable between the Drive Module and the Drive Module is connected at
delivery.
The following procedure describes exceptions from the standard delivery, when the cable
must be connected to the Control Module after delivery.
Action Note/Illustrator
1. Lead the harness through the Connectors on the Control Module are described in
cable gland, into the Control section, Connectors on controller, IRC5 on page 47
Cabinet.

Continued
2. Loosen the contact behind the
main switch of the Control
Cabinet.
xx0600003367
A - Connect
3. Connect the two power cables
from the harness to the
contacts marked 1L1 and 3L2
on the contact.

xx0600003368
4. Strap the cabling to existing

straps inside the module.
To Drive module
Connecting power to the Drive Module is done exactly as for the Single Cabinet Controller,
see Connecting power supply to the Single Cabinet Controller on page 58.
2.5.7. Connecting the communication cabling for the Dual Cabinet Controller
General
Normally the communication cabling between the Control Module and Drive Module are
installed at delivery.
The following procedures describes exceptions from the standard delivery, when the cables
must be connected to the Control Module after delivery.
Communication cabling
The communication cabling are delivered with the Drive Module, and consists of the
following cables:
• Ethernet cable
• Safety cable
Location
xx0600003365
A Ethernet cable
B Safety cable

Continued
Procedure
The procedures below details how to install the communication cabling.
The placement of Computer unit, Axis computer, Panel unit and Contactor board are
described in the repairs section respectively.
1. Lead the Ethernet and
safety cables from the
front of the Drive Module
to the back of the Control
Module. Lead the cables
into the Control Module
through the cable glands
on the back.
xx0600003367
2. Connect the Ethernet

cable to the main
computer, contact
A32.A9. The contact is
marked with AXC1.
Connect the safety cable
to the panel board,
contact A21.X7.
xx0600003370
3. Strap the cabling to

existing straps inside the
module.
2.5.8. Fitting the connector
General
This section details how to fabricate a cable for connecting the mains power to the Drive
Module.
Specifications
The following details the cable and fuse requirements for the mains power connection to the
Drive Module.
Component Description
Cable typ Flexible oil resistant rubber
Cable area 4 x 6mm2
Fuse Delay action fuse 25A
Included parts
The following parts are included in the delivery.
Part Qty
Female contact 1
Contact housing 1
Brass cable clamp with gasket 1
Procedure
The following details how to fit the connectors
1. Select a suitable three phase + earth cable and cut See specifications above.
it to desired lenght.
2. Make sure all parts required are available. Specified in Included parts above.

Continued
3. Fit the cable through the hosing and the brass cable
clamp, and connect the wires to the female
connector.
xx0400001044
• A: housing
• B: Brass cable clamp
• C: female connector
4. Connect the wires according to the illustration.
xx0400001045
• X0.1 - phase 1
• X0.2 - phase 2
• X0.3 - phase 3
• X0.PE - earth wire
5. Assemble the connector by fitting the housing and
the brass cable clamp.
2.5.9. Connecting the manipulator to the IRC5 controller
2.5.9. Connecting the manipulator to the IRC5 controller
General
Connect the manipulator and IRC5 controller to each other after installing them. The lists
below specify which cables to be used in each application.
All connectors on the IRC5 controller are shown in section Connectors on controller, IRC5
on page 47.
Main cable categories

All cables between manipulator and IRC5 controller are divided into the following
categories:
Cable category Description

Manipulator cables Handles power supply to and control of the
manipulator's motors as well as feedback
from the serial measurement board.
Position switch cables (option) Handles supply to and feedback from any
position switches.
Customer cables (option) Handles communication with equipment fitted
on the manipulator by the customer.
Additional axes cables (option) Handles power supply to and control of the
external axes motors as well as feedback
from the servo system.
These categories above are divided into sub-categories which are specified in section
Manipulator cables on page 328.
2.5.10. The MOTORS ON/MOTORS OFF circuit
Outline diagram
The MOTORS ON/MOTORS OFF circuit is made up of two identical chains of switches.
The diagram shows the available customer connections, AS, GS, SS and ES.
A
E
B C C
D
G F
J
&
P S
R T
K
M N
O
xx0100000174
A ES (emergency stop)
B LS (Limit switch)
C Solid state switches
D Contactor
E Mains

F Drive unit
G Second chain interlock
H GS (general mode safeguarded space stop)
J SS (superior stop, same function as GS)
K AS (Automatic mode safeguarded space stop)
L ED (TPU enabling device)
M Manual mode
N Automatic mode
O Operating mode selector
P RUN
R EN1
S EN2
T Motor

Continued
Function of the MOTORS ON/MOTORS OFF circuit

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

The diagram below shows the dual channel safety chain.
The supply from internal 24V and 0 V is displayed. For external supply of GS and AS check
the circuit diagram.
Te r m i n a l Lo c a t io n
X5,X6 C o n t r o l M o d u le
X22,X24 D riv e M o d u le
xx0100000166
Technical data per chain

Limit switch Load: 300 mV
Max. voltage drop: 1 V
External connectors Load: 10 mA
Max. voltage drop: 4 V
GS/AS/SS load at 24 V 25 mA
GS/AS/SS closed "1" >18 V

Continued
Technical data per chain

GS/AS/SS open "0" <5V
External supply of GS/AS/SS Max. + 35 VDC
Min. - 35 VDC
GS/AS/SS Filter time 2,0 ms1)
Max. potential in relation to the 300 V
cabinet earthing and other signal
groups.
Signal class Control signals
1) When connecting e.g. a Safety PLC to a safety stop, make sure that the safety check pulses
not exceeds 2,0 ms, otherwise a safety relay must be connected in between. See illustration
below.
IRC5
PLC
Panel board (A21) Safet y relay
Contact X5
X5.11 (AS1+)
X5.12 (24 V)
X5.3 (AS2-)
X5.1 (0 V)
xx0800000130

Continued
Connection of ES1/ES2 on panel unit

The diagram below shows the terminals for the emergency circuits.
The supply from internal 24V (X1/X2:10) and 0V (X1/X2:10) is displayed. For an ext.
supply, X1:3 / X2:9 is connected to ext. 24V, and X1:9 / X2:3 is connected to ext. 0V (dotted
lines).
A
24V 0V
B C D
X1:4 X1:3
X1:9
X1:10
X1:8 X1:7
X1:1
X1:2
24V
X1:6
E
24V
X1:4
X1:5
G
0V 24V
F
B C D
X2:4 X2:3
X2:9
X2:10
X2:8 X2:7
X2:1
X2:2 0V
X2:6
H
0V
X2:4
X2:5
J
xx0100000191
A Internal
B Ext stop
C FlexPendant
D Cabinet
E ES1 internal
F Run chain 1 top
G Internal
H ES2 internal
J Run chain 2 top
Continued
Technical data
ES1 and ES2 max output voltage 120 VAC or 48 VDC
ES1 and ES2 max output current 120 VAC: 4 A
48 VDC L/R: 50 mA
24 VDC L/R: 2 A
24 VDC R load: 8 A
External supply of ES relay 24 VDC ± 10% between terminals X1:9,
8 and X2:9, 8 respectively.
Note! In case of interference, the
external supply must be properly filtered.
Rated current per chain 40 mA
Max. potential in relation to the cabinet earthing 300 V
and other signal groups.
Connection to operating mode selector (Option)

The illustration below shows the connection of terminals for customer use.
xx0500002092
A Mode selector © Copyright 2004-2008 ABB. All rights reserved.
External manual FS (Full Speed) 100% is an option.
Technical data
Max. voltage 48 VDC
Max. current 4A
2.5.11. Connection of external safety relay
2.5.11. Connection of external safety relay
Description
The motor contactors K42 and K43 in the Drive Module can operate with external equipment
if external relays are used.
The figure below shows an example of how to connect an external safety relay.
Connection example
xx0100000246
C Robot 1
D Robot 2
F ES (emergency stop) relay
G External Safety relay
H To other equipment
J Safety gate
K Cell ES (emergency stop)
2.5.12. Connection to MOTORS ON/MOTORS OFF contactor
General
This section details connection to the MOTORS ON/MOTORS OFF contactor. To be used
when the customer wants external equipment to follow the robot control.
Location
The MOTORS ON/MOTORS OFF contactor is located on the left hand side in the Drive
Module.
A
C
D
xx0400001058
A MOTOR ON contactor K42 / K43

B Contactor auxilary block 33-34
C Brake contactor
D Jumper (3 pcs)
E Contactor interface board
Required equipment

The table below details the required equipment.
Equipment Note
Standard toolkit
Technical data
The table below shows technical data.
Technical data
Max. voltage 48 VDC
Max. current 4A

Continued
Procedure
Following procedure details connection to the MOTORS ON/MOTORS OFF contactor.
1.
DANGER!
Before any work inside the cabinet, please observe the safety
information in section DANGER - Make sure that the main power
has been switched off! on page 28.
2. Connect the wires to the contactor auxilary blocks 33-34,
according to the diagram to the right.
xx0400001231
2.5.13. Connection of Drive Module Disconnect, by limit switch
General
This function enables you to temporarily disconnect a Drive Module and deactivate any robot
or additional mechanical units connected to this module. The procedures are detailed below.
It is also possible to connect a remote switch to enable a Drive Module Disconnect. The
required equipment and procedure for connection of a switch are specified below.
NOTE!
The system diagnostics monitors the connection and disconnection of Drive Modules, and
event log messages regarding these events will be stored in the event log when required.
These messages are accessible using the FlexPendant or RobotStudio.
Location
The contactor interface board unit is located on the left hand side of the controller as shown
below.
In the Dual Cabinet Controller, the board is located in the Drive Module.
xx0500001951
A Contactor interface board

B Contactors
C Drive system power supply
D Customer I/O power supply
E Control power supply
F Backup energy bank

Continued
Required equipment
Equipment Note
Wire AWG20
Switch 24V 0,5A
Operating manual - RobotStudio
Operating manual - IRC5 with FlexPendant
Standard toolkit
Enabling a Drive Module Disconnect in RobotStudio

The following procedures details how to enabeling the system for a Drive Module
Disconnect.
Action
1. In RobotStudio, select the Topic: Motion.
2. Select Type: Drive Module User Data .
3. Set the parameter for selected drive module to YES.
4. Restart the system.
(Warm start)
Enabling a Drive Module Disconnect with the FlexPendant

The following procedures details how to enabeling the system for a Drive Module
Disconnect.
Action
1. On the FlexPendant, Tap ABB and then Tap Control Panel.
2. In the Control panel menu, Tap Configuration.
3. In the Configuration menu, Tap Topics, and select Motion.

4. In the Topic: Motion, Tap Type: Drive Module User Data.
5. Tap selected drive module.
6. Tap the parameter in order to modify it.
7. Restart the system (warm start).
Disconnect the Drive Module

The following procedure details how to disconnect a Drive Module.
1. Make sure that the system is in the
MOTORS_OFF state.

Continued
2. Disconnect the connector X22. It is also possible to use connector X21,
but this is typically used for limit switches
on the robot.
xx
Reconnect the Drive Module

The following procedure details how to reconnect the Drive Module.
MOTORS_OFF state.
2. Reconnect the X22 connector.
xx0500002087
3. Move the program pointer to main in the

RAPID-program where the disconnected
mechanical units are active.
Connect a remote switch
The following procedures details how to connect a remote switch.
MOTORS_OFF state.
2. Disconnect the jumpers from the connector
X22.

Continued
3. Connect the wires to the connector X22
according to the diagram on the right.
xx0500002091
2.5.14. Connection of servo disconnect, by servo power switch
General
The IRC5 controller is pre-wired to accept a customer servo disconnect.
NOTE!
Due to risk of voltage drop, the switch to the servo disconnect circuit should not be mounted
more than 50 meters from the Drive Module.
Location
The contactor is found on the left hand side inside the Drive Module as shown below.
A
C
D
xx0400001058
A MOTOR ON contactor K42 / K43

B Contactor block3
C Brake contactor
D Jumper (4 pcs)
Required equipment

Equipment Note
Wire AWG 10, brake AWG 16
Switch 500V 40 A, brake 24V 10A
Standard toolkit

Continued
WARNING!
It is recommmended to also open the 24V to the brake (wire 489) to avoid accidental release
of the brakes when the drive system is disconnected.
Procedure
Following procedure details how to connect a servo disconnect.
1.
DANGER!
Before any work inside the cabinet,
please observe the safety information in
section DANGER - Make sure that the
main power has been switched off! on
page 28.
2. Remove the four jumpers between The jumpers are shown in Location.
contactors R2 and R3
3. Connect the wires according to the
diagram on the right.
xx040000
• A: MOTOR ON contactor K43

• B: Jumper (4 pcs)
• C: MOTOR ON contactor K42
• D: Wires to external main switch
• E: External switch
2.5.15. Connecting a Limit switch override push button
DANGER!
The Limit switch override is used to disconnect safety limitations. Make sure the Limit switch
override function is not active longer than absolutely necessary.
If the option SafeMove is implemented, Limit switch override must never be used at all. The
SafeMove safety controller has its own override function.
General
The override circuit enables the possibility to jog an axis out of a forbidden (limited) zone.
Limitations
The switch has to be placed inside the controller to eliminate the risk of electrical noise.
Required equipment
Equipment Art. no Note

Contact block 1SFA 610 605 R1001 ABB CW Control
Contact blocks with holder 1SFA 611 605 R1201 ABB CW Control
Push button (in Dual Cabinet) 1SFA 611 102 R1105 ABB CW Control
Connector X23 1SSA 245 204 R0100 ABB CW Control
Wire Cable AWG 20 Blue
Standard toolkit Described in section,
Standard Toolkit.
Circuit diagram See Circuit Diagram on
page 341
Procedure for Single Cabinet Controller

The following procedure details how to connect a Limit switch override circuit in a Single
Cabinet Controller.
Action Note/illustration © Copyright 2004-2008 ABB. All rights reserved.
1.
Danger
DANGER!
Before any work inside the IRC5 controller
modules, please observe the safety
information in section DANGER - Make
sure that the main power has been
switched off! on page 28.

Continued
2. Attach two additional contact blocks on the
existing push button (Motors on).
A
note
Note!
There is only room for one additional
contact block beside the two existing. B
Therefor, place one additional block on top
of the other.
C
D
xx0500002553
• A: Additional contact blocks

• B: Existing contact, lamp blocks
• C: Holder
• D: Push button
3. Connect wires from the contact blocks to
the connector according to the diagram to
the right.
xx0500002556

Continued
4. Route the wires together with the existing
harness on the left wall.
xx0500002557
• A: Contact blocks
• B: Wires
• C: Connector X23
5. Fit the connector to the X23 connector on
the contactor interface board.

xx0500002087

Continued
Procedure for Dual Cabinet Controller

The following procedure details how to connect a Limit switch override circuit in a Dual
Cabinet Controller.
1.
Danger
DANGER!
Before any work inside the IRC5 controller
modules, please observe the safety
information in section DANGER - Make sure
that the main power has been switched off! on
page 28.
2. Disconnect the two wires from the signal lamp
block.
3. Remove the signal lamp from the operator’s
panel on the Drive Module.
xx0500002563
• A: Signal lamp
• B: Attachment nut
4. Fit the push button with holder and contact
and lamp blocks in the existing hole of the

signal lamp.
B
C
xx0500002554
• A: Contact, lamp blocks

• B: Holder
• C: Push button
5. Reconnect the two wires from signal lamp to
the new lamp block.

Continued
6. Connect wires from the contact blocks to the
connector according to the diagram to the
right.
xx050000
7. Route the wires together with the existing

harness on the left wall.
xx0500002564
• A: Contact block
• B: Wires
• C: Connector X23
8. Fit the connector to the X23 connector on the
contactor interface board.
xx0500002087
2.6.1. Drive functions, general
2.6 Drive system
2.6.1. Drive functions, general
General
The manipulator is powered by power electronics found in the IRC5 controller, (for the Dual
Cabinet Controller it’s found in the Drive Module). This also includes power electronics for
driving external axes.
Standard configurations
The drive system (drive units, rectifier and capacitor unit) is available in two sizes depending
on which robot to drive and other power requirements.
How to configure the drive system is detailed in, Configuration of the drive system, IRC5 on
page 88
Install drive system parts

How to install the drive system parts is detailed in section Installation of Drive system parts
on page 111
2.6.2. Configuration of the drive system, IRC5
General
The IRC5 Single Cabinet Controller contains a number of drive units, rectifiers and filters.
Any allowed combination of these, depending on the robot type, is specified below.
The robot system may also be equipped with up to three additional drive modules, which are
described in the Product manual - IRC5, section Installation of additional drive module.
Location
The servo drive units, rectifiers and capacitor units are located in the Single Cabinet
Controller as shown below.
xx0500001858
Description
A Operator’s panel
B Capacitor

C Computer unit
D Panel unit
E Axis computer
F Drive system, (drive units and rectifier)
DC busbars
Between the units are fitted DC-busbars, which are specified below:
Description Art. no. Note

DC-bus bar 3HAC17281-1 DC_L6: long busbar with six connector groups
DC-bus bar 3HAC17281-3 DC_S2: short busbar with two connector groups
Servo drive dummy 3HAC17282-1 -

Continued
IRB 140
The figures show the drive unit with and without additional axes respectively. The table
specifies which units may be fitted in which positions.
xx0200000121
xx0200000120
Pos. Identification Description Art. no. Note

1 DSQC 620_C2 Capacitor unit 3HAC14551-1 Only in system
with two external
axes, size U
Z2 DSQC 618_RC1 Rectifier 3HAC14549-1 In systems

without external
axes only!
Z2 DSQC 618_R2 Rectifier 3HAC14549-2 In systems with
external axes
only!
Z3, Y3, DSQC 617_3B3A Main Drive unit 3HAC025338-001 Z3 - X3 is ONE
X3 unit!
Z4, Y4, DSQC 619 Optional drive 3HAC14550-1 Size: 1C
X4 units for 3HAC14550-2 Size: 1T
additional axes 3HAC14550-3 Size: 1U

Continued
IRB 340, 360

xx0200000121
xx0200000120

1 DSQC 620_C2 Capacitor unit 3HAC14551-1 In systems with
external axes

only!
with two external
axes, size U
Z2 DSQC 618_RC1 Rectifier 3HAC14549-1 In systems
without external
axes only!
external axes
only!
Z3, Y3, X3 DSQC 617_3E1C Main Drive unit 3HAC025338-003 Z3 - X3 is ONE
unit!
Z4, Y4, X4 DSQC 619 Optional drive 3HAC14550-1 Size: 1C
units for 3HAC14550-2 Size: 1T

Continued
IRB 1400
xx0200000121
xx0200000120

1 DSQC 620_C4 Capacitor unit 3HAC14551-3 Only in system with
two external axes,
size U
Z2 DSQC 618_RC1 Rectifier 3HAC14549-1 In systems without

external axes only!
external axes only!
Z3, Y3, DSQC 617_3B3A Main Drive unit 3HAC025338-001 Z3 - X3 is ONE unit!
X3
Z4, Y4, DSQC 619 Optional drive 3HAC14550-1 Size: 1C
X4 units for 3HAC14550-2 Size: 1T

Continued
IRB 2400
xx0200000121
xx0200000120

with two external
axes, size U
Z2 DSQC 618_RC1 Rectifier 3HAC14549-1 In systems © Copyright 2004-2008 ABB. All rights reserved.
without external
axes only!
external axes
only!
Z3, Y3, X3 DSQC 617_2E2C2B Main Drive unit 3HAC025338-002 Z3 - X3 is ONE
unit!
Z4, Y4, X4 DSQC 619 Optional drive 3HAC14550-1 Size: 1C

Continued
IRB 4400
X Y Z
1
Rectifier: Z2
Capacitor: 1
Main drive unit: Z4 - X3
Single drive unit: 7=Y2/8=X2
xx0300000184

1 DSQC 620_ C4 Capacitor unit 3HAC14551-3
Z2 DSQC 618_R2 Rectifier 3HAC14549-2
Y2, X2 DSQC 619 Optional drive 3HAC14550-1 Size: 1C
Z4, Y4, X4, Z3, DSQC Main Drive unit 3HAC025338-004 Z4 - X3 is ONE
Y3, X3 617_3G3T unit!
IRB 6400RF
X Y Z
1
Rectifier: Z2
Capacitor: 1
xx0300000184

Continued

1 DSQC 620_C4 Capacitor unit 3HAC14551-3
Y2, X2 DSQC 619 Optional drive units 3HAC14550-4 Size: 1W
for external axes
Z4, Y4, X4, DSQC Main Drive unit 3HAC025338-006 Z4 - X3 is
Z3, Y3, X3 617_3V3W ONE unit!
IRB 6600, 7600

X Y Z
1
Rectifier: Z2
Capacitor: 1
xx0300000184

1 DSQC 620_C3 Capacitor unit 3HAC14551-2
Y2, X2 DSQC 619 Optional drive units 3HAC14550-4 Size: 1W
for external axes
Z4, Y4, X4, DSQC 617_3V3W Main Drive unit 3HAC025338-006 Z4 - X3 is © Copyright 2004-2008 ABB. All rights reserved.
Z3, Y3, X3 ONE unit!
Drive unit connection

The table below shows the drive unit connection for each drive unit.
Designation in Template file name

Main drive unit Power stage
circuit diagram (drive unit name)
DSQC 617_3B3A • B M1 (R,S,T)b M1 (DMX)c
Used for irb 140 • B M2 (R,S,T) M2 (DMX)
• A M3 (R,S,T) M3 (DMX)
• A M4 (R,S,T) M4 (DMX)
• B M5 (R,S,T) M5 (DMX)
• A M6 (R,S,T) M6 (DMX)

Continued
Designation in Template file name

Main drive unit Power stage
circuit diagram (drive unit name)
DSQC 617_2E2C2B • E M1 (R,S,T)b M1 (DMX)c
Used for irb 1400, 1600, 2400 • E M2 (R,S,T) M2 (DMX)
and 260 • B M3 (R,S,T) M3 (DMX)
• B M4 (R,S,T) M4 (DMX)
• C M5 (R,S,T) M5 (DMX)
• C M6 (R,S,T) M6 (DMX)
DSQC 617_3E1C • E M1 (R,S,T)b M1 (DMX)c
Used for irb 340, 360 • E M2 (R,S,T) M2 (DMX)
• - - -
• - - -
• E M3 (R,S,T) M5 (DMX)
• C M4 (R,S,T) M6 (DMX)
DSQC 617_3G3T • T M1 (R,S,T)b M1 (DMX)c
Used for irb 4400 • G M2 (R,S,T) M2 (DMX)
(With option only 4 active • T M3 (R,S,T) M3 (DMX)
drives node 4 and 6 are not • G M4 (R,S,T) M4 (DMX)
used.) • T M5 (R,S,T) M5 (DMX)
• G M6 (R,S,T) M6 (DMX)
DSQC 617_3V3W • W M1 (R,S,T)b M1 (DMX)c
Used for irb 660, 6600, 6650, • V M2 (R,S,T) M2 (DMX)
7600 and 6400RF • W M3 (R,S,T) M3 (DMX)
(With option only 4 active • V M4 (R,S,T) M4 (DMX)
drives node 4 and 6 are not • W M5 (R,S,T) M5 (DMX)
used.)
• V M6 (R,S,T) M6 (DMX)
b
Phase R,S,t (U,V,W).
c
X= drive module number.
For details about the connection pins, see Circuit Diagram on page 341.
2.7.1. Memory functions, IRC5
2.7 Memory functions
2.7.1. Memory functions, IRC5
General
The controller may be fitted with memory functions found inside the Computer Module.
The memory functions are divided into two main categories:
• Mass memory (hard disk drive, solid state disk drive, etc)
• RAM memory (memory modules fitted on the main computer motherboard)
Computer units
Computer unit DSQC623:
• Computer Module BD plus features a hard disk drive containing ABB VxWorks boot
image software.
• Computer Module AC plus features a IDE Flash Module 256MB drive containing
ABB VxWorks boot image software.
• 256 MB SDRAM memory (Synchronous Dynamic Random Access Memory).
Computer unit DSQC639:
• Compact flash memory 256MB containing ABB VxWorks boot image software.
• 256 MB DDR SDRAM memory (Synchronous Dynamic Random Access Memory).
Note
NOTE!
Only use Compact flash memory and DDR SDRAM memory supplied by ABB.
Further information
The table gives references to additional information.
Information: Found in:

How to replace malfunctioning Section Replacement of hard disk or IDE Flash module
memory units and restore the drive and cable in computer unit DSQC623 on page
system to full operation: 268orReplacement of Compact Flash memory in
computer unit DSQC639 on page 272
SectionReplacement of motherboard in computer unit
DSQC623 on page 230orReplacement of motherboard
in computer unit DSQC639 on page 235.
Section Replacement of DDR SDRAM memory on
motherboard in computer unit DSQC639 on page 240
Note that the DRAM modules on the Computer unit
DSQC623 motherboard cannot be replaced
separately! Replacing the DRAM modules entails
replacing the complete motherboard!
2.7.2. Connecting a USB memory to the computer unit
Location DSQC623
A USB memory may be connected to either one of the USB ports on the computer unit. The
USB ports are shown in the figure below:
xx0400000939
B Console
C COM1
D USB 1, 2 computer unit (USB 2 is normally connected to power supply supervision)
E USB 3, 4 computer unit (Not used)
F LAN
G A33 Profibus DP M/S, A37 Interbus M/S (optical fiber), A38 Interbus M/S (copper wire),
A35 Devicenet
H X1
J PWR (green)
K HDD (yellow)
L A32 RCC

Continued
Location DSQC639
A USB memory may be connected to either one of the USB ports on the computer unit. The
USB ports are shown in the figure below:
xx0600002895
A USB 1, 2 The USB connectors provide two legacy USB 2.0 ports supporting High

Speed/Full Speed/Low Speed (HS/FS/LS)
Connection
Action Info/illustration
1. Open the connector cover on the controller or open the
door, (Control Module on the Dual Cabinet).
xx0600002894
• A: USB port
Continued
Action Info/illustration
2. Remove the end cover on the USB memory and connect The USB memory and its
it to the connector. contents may now be
Do not disconnect the USB memory approx. 10 seconds accessed from the computer
after connecting it. unit just as any other hard
drive unit.
3.
CAUTION!
CAUTION!
Handling of USB memory is described in Operating
manual - IRC5 with FlexPendant, section File Managing.
2.8.1. Definition of I/O units, IRC5
2.8 I/O system
General
The IRC5 controller may be fitted with I/O, Gateway or Encoder units. These are configured
in an identical way.
The IRC5 Single Cabinet Controller is prepared for up to two I/O units, Gateways or Encoder
interfaces units, and the Dual Cabinet Controller (Control Module) is prepared for up to four
I/O units, Gateways or Encoder interface units. This means that the harness inside the IRC5
controller is equipped with necessary connectors.
For the Single Cabinet Controller the I/O, Gateway or Encoder units are placed on the inside
of the door as shown in the illustration below. For the Dual Cabinet Controller the units are
mounted in the Control Module.
xx0500001859

A I/O, Gateway or Encoder units
B Mounting rail
Standard configuration
In the standard form, no fieldbus is mounted to the controller. However, the digital inputs and
outputs are available on the customer plate in the control module.
It is possible to connect any type of DeviceNet compliant I/O unit on the DeviceNet
- master bus. All I/O units should comply with the DeviceNet standard and be
conformance tested by ODVA.

Continued
I/O units
The table below specifies the I/O units:
Description Note
AD Combi I/O DSQC 651
See I/O System parts on page 323 for the
spare part number
Digital I/O DSQC 652
spare part number
Digital I/O with relay outputs DSQC 653
spare part number
Analog ±10 V I/O DSQC 355A
spare part number
Gateways
The table below specifies the Gateways:

DeviceNet/Allen Bradely Remote I/O 3HNE00025-1 DSQC 350A
Gateway
DeviceNet/Interbus Gateway 3HNE00006-1 DSQC 351A
DeviceNet/Profibus DP Gateway 3HNE00009-1 DSQC 352A
Encoder interface units

The table below specifies the encoder interface units:

Encoder interface unit for conveyor 3HNE01586-1 DSQC 377A.
tracking
Further information
The table below gives references to additional information:
Information: Found in:

How to install the I/O units and Section Installation of I/O, Gateways and encoder
Gateways mechanically and electri- interface units, IRC5 on page 113.
cally.
Allowed configurations of I/O units Technical reference manual - System parameters
and how to setup the configurations.
How to install the I/O unit and The Application manual for the different I/O buses
Gateways software related in a new respectively.
system.
Detailed descriptions of all available The Application manual for the different I/O buses
I/O units and Gateways. respectively.

2.9.1. Installation of additional Drive Module
2.9 Installation of add-ons
General
To be able to use a Multi Move system or to control more than 3 additional axes, an additional
Drive Module is needed. The IRC5 controller is prepared for up to three additional Drive
Modules.
xx0400001042
Prerequisites
Equipment Note
AdditionalDrive Module (Includes all cabling and Specified in Specification Form
required mounting hardware)
Ethernet board DSQC 612
See Computer unit DSQC 623 parts on
page 324Computer unit DSQC 639 parts
on page 325 for the spare part number
Standard toolkit The contents are defined in section
Standard toolkit!
Other tools and procedures may be required. These procedures include references to
See references to these procedures in the step- the tools required.
by-step instructions below.

Procedure
The procedure below details how to install the additional drive module.
1.
DANGER!
please observe the safety
information in section DANGER -
Make sure that the main power has
been switched off! on page 28.

Continued
2.
esd
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the
safety information in section
WARNING - The unit is sensitive to
ESD! on page 29
3. Fit the DSQC 612 Ethernet board How to fit the Ethernet board is detailed in section
into the computer unit. Replacement of PCI boards in the computer unit
DSQC639 on page 249orReplacement of PCI
cards in the computer unit DSQC623 on page
245
4. Place the additional drive module in
position and secure it with the
included screws and washers.
5. Remove the top cover.
xx0500001887
Parts:
• A: top cover
• B: attachment screw (4pcs)

Continued
6. Loosen the attachment screws, and
remove the cover to a empty slot in
the back of the controller.
xx0500001888
• A: cover
• B: attachment screw (2pcs)
7. Fit the communication cabling with Single Cabinet:
cover with two attachment screws.
When connecting the 4:th Drive

Module (MultiMove system) to a
Dual Cabinet, strap the cables
according to the image.

xx0500001889
Dual Cabinet:
xx0700000415
• A: cable strap

Continued
8. Connect the ethernet cable
(A32.X9) to the DSQC 612 Ethernet
board.
Connector:
• A32.X9 to Ethernet board
connector, AXC1
9. Connect the safety signal cable
(A21.X7) to the Panel board.
Connector:
• A21.X8 - 1 additional drive
• A21.X14 - 2 additional drives
• A21.X17 - 3 additional drives
xx0400001890
10. Strap the cabling to existing straps

inside the module.

2.9.2. Installation of external operator's panel, IRC5
Location
An external operator's panel may be fitted in a separate wall cabinet as shown in the
illustration below.
xx0400000956
A Wall cabinet IRC5

B Bracket
C FlexPendant holder
D Emergency stop button
E Motor ON button
F Position mode switch
G External Operator's panel harness

H FlexPendant connector
Required equipment
Equipment Art. no. Note

Wall cabinet IRC5 3HAC022035-001
External Operator's panel 3HAC021273-005 30 m
cable 3HAC021273-001 22 m
3HAC021273-006 15 m
section, Standard Toolkit.
Other tools and procedures These procedures include
may be required. See references to the tools
references to these required.
procedures in the step-by-
step instructions below.
Circuit Diagram See Circuit Diagram on page
341
Continued
Procedure
The procedure below details how to install the external control panel.
1.
DANGER!
Before any work inside the cabinet, please
observe the safety information in section
DANGER - Make sure that the main power
2. Disconnect the cable from the ethernet DSQC623:
connector for FlexPendant on the computer
unit.
Slot 1 Slot 2 Slot 3 Slot 4 Slot 5
xx0400000960
• A: Connector X8
DSQC639:
xx0600002897
• A: FlexPendant port
3. Disconnect signal cabling from the panel
board unit.
Connectors:
• A21.X9
• A21.X10
xx0500001890

Continued
4. Remove the cover to a free customer The illustration below shows the
connector slot on the connection panel. connection panel for the Dual Cabinet
Controller.
xx0400000966
• A: Customer connection slot

The illustration below shows the
connection panel for the Single Cabinet
Controller.
xx0500001960
• A: Customer connection slot

5. Fit the Harness from the external control
panel to the empty slot with the four
attachment screws.
6. Connect the earth cable to the chassi.
A
xx0700000619
• A: earth cable

Continued
7. Connect the ethernet connector A32.A8 to DSQC623:
the computer unit.
xx0400000960
• A: Connector X8
DSQC639:
xx0600002897

Continued
8. Connect the signal connectors A21.X9 and
A21.X10 to the connector X9 and X10 on
the panel board unit.
xx0500001890
xx0600003257
9. Strap the cabling to the existing cable

straping inside the module.
10. Fit the cabling to the wall cabinet with the
two attachment screws.
11. Connect the connectors inside the wall Connectors inside wall cubicle.

cabinet. • A21.X9 to X9
• A22.X2 to X2
• A22.X3 to X3

2.9.3. Installation of Drive system parts
Location
The illustration below shows the location of the drive system in a Single Cabinet Controller,
in a Dual Cabinet Controller the drive system components are located in the Drive Module.
xx0500001858
B Capacitor
C Computer unit
D Panel unit
E Axis computer
F Drive units/Rectifier
Required equipment

A number of choices are Specified in section Configuration
available of the drive system, IRC5 on page
88.
section Standard toolkit.
Other tools and procedures may These procedures include
be required. See references to references to the tools required.
these procedures in the step-by-
Application manual - Additional 3HAC021395-001 Contains information on how to
axes and stand alone controller configure the system for
additional axes.
Continued
Procedure
The procedure below details how to install a drive unit.
1.
DANGER!
2. Remove the dummy by unscrewing its Location is detailed in section Location on
attachment screws. page 111.
xx0500001843
Parts:
• A: dummy
• B: drive unit
• C: attachment screw
3. Fit the drive unit in position. Allowed positions are specified in section
Secure it with its attachment screws. Configuration of the drive system, IRC5
on page 88
4. Connect any additional connectors to the © Copyright 2004-2008 ABB. All rights reserved.
unit.
5. Make sure the robot system is configured Basic robot drive functionality is
to reflect the drive functions installed. configured in System Builder in
RobotStudio.
Additional axes detailed in documents
specified above!

2.9.4. Installation of I/O, Gateways and encoder interface units, IRC5
Location in Single Cabinet Controller

The location for the I/O units, Gateway or encoder interface units to be installed are shown
in the illustration below.
xx0500001859
A I/O units, Gateways or encoder interface units

B Mounting rail
Location in Dual Cabinet Controller

The location of I/O units, Gateways or encoder interface units in the Dual Cabinet Controller
is shown in the illustration below.
xx0600002684
A I/O units, Gateways or encoder interface units
Required equipment

I/O units, Gateways or encoder Specified in Definition of
interface units I/O units, IRC5.
Application manual - DeviceNet 3HAC020676-001
Circuit Diagram See Circuit Diagram on
page 341

Continued
Fitting
The procedure below details how to fit the units.
1.
DANGER!
2. Fit the I/O unit by snapping it onto the
mounting rail.
3. Connect the DC supply to the board.
4. Connect wires to the inputs and output Detailed in the Application manual for the
connectors as required. respective busses.

2.9.5. Installation of PMC-card for Force Control Function
Location
The PMC-card shall be mounted on the axis computer card. The axis computer is located as
shown in the illustration below.
xx0500001858
B Capacitor
C Computer unit
D Panel unit
E Axis computer
F Drive system (drive units and rectifier)
Required equipment

6-DOF sensor ATI
PMC-card Supplied with the sensor
Cable between the sensor and PMC-card Supplied with the sensor
RW Force Control Software Option no:
Assembly: 661-2
Application manual - Force Control 3HAC025057-001
Assembly
Operating manual - RobotStudio 3HAC032104-001
Standard tool kit.

Continued

Circuit diagram See Circuit Diagram on
page 341
Procedures
The following procedures details how to install the PMC-card on the axis computer card.
1.
DANGER!
Before any work inside the cabinet, please observe
the safety information in section DANGER - Make
sure that the main power has been switched off! on
page 28.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD! on
page 29
3. Remove the attachment screws and pull out the
axis computer. A
B B
xx0500002002
• A: axis computer
• B: attachment screws

Continued
4. Remove the six attachments screws on the sides of
the axis computer, and remove the back cover.
xx0500002134
• A: back cover
• B: attachment screw
(6pcs)
5. Remove the eight attachment screws holding the
board to the front cover, and lift out the board.
xx0500002137
• A: axis computer board

• B: front cover
• C: attachment screw
(8pcs)
6. Mount the PMC-card according to the picture, and
secure it with the four attachment screws.
xx0500002138
• A: PMC-card with
attachment screws
• B: axis computer board

Continued
7. Refit the axis computer in controller.
A
B B
xx0500001885
8. Install the Force Control software. Installation of the software is

described in Operating manual -
RobotStudio

2.9.6. Installation of extra mass memory in computer unit DSQC623
Location
The mass memory is located in the Computer unit as shown in the figure below.
xx0400000883
A Bay for hard disk (Optional)

B X1 Power supply connector
C PWR (green)
D HDD (yellow)
E A32 RCC
F Console
G COM1
H USB 1, 2 computer unit
J USB 3, 4 computer unit (USB 3 is normally connected to power supply supervision)
K LAN
L A33 Profibus DP M/S, A37 Interbus M/S (optical fiber), A38 Interbus M/S (copper wire),
A35 Devicenet, Multi Move Ethernet card.
Prerequisites
Equipment Note
A number of versions are available! Available components for each robot version is
specified in section Definition of Memory
Functions, IRC5.
Standard toolkit The contents are defined in section Standard
toolkit!
Other tools and procedures may be These procedures include references to the
required. See references to these tools required.
procedures in the step-by-step instructions
below.

Continued
Procedure Hard disk drive

The procedure below details how to install the extra mass memory.
1.
DANGER!
2.
esd
WARNING!
handling the unit please observe the safety
information in section WARNING - The unit
is sensitive to ESD! on page 29
3. Remove the computer unit. Detailed in section Replacement of
computer unit DSQC623 on page 222.
4. Open the computer unit Detailed in section Replacement of
motherboard in computer unit DSQC623
on page 230.
5. Unscrew the cage attachment screws for Detailed in section Replacement of
the drive cages, and pull the cage out. motherboard in computer unit DSQC623
on page 230.
6. Disconnect the flat ribbon cable from the
hard disk drive memory.
xx0400000941
• A: Hard disk drive

• B: Flat ribbon cable connection, 40
pin

Continued
7. Disconnect the flat ribbon cable from the
IDE connector on the motherboard.
xx0400000895
• A: IDE connector
8. Connect the included flat ribbon cable to the
9. Reconnect the flat ribbon cable to the mass
memory units.
xx0400000941
• A: Hard disk, solid state drive

• B: Flat ribbon cable connection, 40
pin
10. Make sure if the drives are to be defined as How to define the unit is shown on a
"Master". sticker on the unit.
11. Push the cage back in to the computer unit,
and secure it with the attachment screws.
12. Make sure no cable is damaged, and close Detailed in section Replacement of
the computer unit. motherboard in computer unit DSQC623

on page 230.
Procedure IDE flash module

The following procedure details how to install a Solid State Drive.
1.
DANGER!
DANGER - Make sure that the main power has

Continued
2.
esd
WARNING!
section WARNING - The unit is sensitive to
ESD! on page 29
3. Remove the computer unit. Detailed in section, Replacement of
computer unit DSQC623 on page
222.
4. Open the computer unit. Detailed in section, Replacement of
motherboard in computer unit
DSQC623 on page 230
5. Locate the IDE connector.
xx0400000895
6. Connect the IDE flash module to the IDE

connector and the power connector to the
connector from the computer power supply.
xx0500001907
Parts:
• A: power connector
• B: IDE flash module

2.9.7. Installation of Euromap and SPI
General
This description contains the specification for the electrical interface between an injection
moulding machine and the ABB robot controller, based on the definitions made by the
Technical Commission of Euromap and SPI (Society of Plastics Industry). There are three
different standards used for the interface between an injection moulding machine and a robot:
• Euromap 67 is the current standard which offers double channel security
• Euromap 12 is used for older injection moulding machines which offer only single
channel security.
• SPI is mainly used in North America and exists in two versions: AN 116 wich is an
older standard and offers single channel safety only (similar to EM 12). AN 146 wich
was introduced in October 2006 and differs from AN 112 in that it supports dual
channel safety and some additional control signals (similar to EM 67).
The robot interface for Euromap 67 and SPI - AN 146 is implemented in the standard IRC5
controller. For Euromap 12 and SPI - AN 116 an additional converter box outside the cabinet
is plugged on the Euromap 67 interface.
Location of Euromap harness in the Single Cabinet Controller

The routing of Euromap harness for the Single Cabinet Controller is shown below.
xx0600002635
A Connector A21.X5, on Panel board

B Connector A21.X1, on Panel board
C Connector A21.X2, on Panel board
Continued
E Relay 24K1 and Relay 24K2

G Position switch terminal XT13
H Euromap 67: Digital 24 VDC I/O (I/O 1) Euromap 12 and SPI: Digital Relay
I/O
K Connector XS13
Location of Euromap harness in the Dual Cabinet
xx0500002634
A Connector A21.X5, on Panel board

B Connector A21.X1, on Panel board
C Connector A21.X2, on Panel board
D XS13 connector
F Euromap 67: Digital 24 VDC I/O (I/O 1) Euromap 12 and SPI: Digital Relay
I/O
H XT31
J Connector XS13 Relay 24K1 Relay 24K2
Required equipment for Euromap 67 (Option no. 671-2)
Equipment Art. number Description Note

Cabling 3HAC025478-001 internal in cabinet Single Cabinet

Continued

Cabling 3HAC024069-001 internal in cabinet Dual Cabinet
Converter box
bracket
eio.cfg pre-configured file Available in RW
CD/Utility
Cable 3HAC024328-001 external cable 10m Option 673-1
Cable 3HAC024328-005 external cable 15m Option 673-2
Digital I/O 3HAC025917-001 Digital 24 VDC I/O DSQC 328A
Digital Relay I/O 3HAC025918-001 Digital Relay I/O DSQC 653
Required equipment for Euromap 12 and SPI (Option no. 671-1)

Euromap 12 and SPI (671-1) includes in addition to Required equipment for Euromap 67
(Option no. 671-2) on page 124 the following equipment.

Converter box converts to Euromap 12 and SPI
from Euromap 67
Bracket 3HAC024435-002 Converter box bracket
Cable 3HAC024195-001 from controller to converter box
Cable 3HAC024330-001 from converter box to IMM 10m Option 673-1
Cable 3HAC024330-004 from converter box to IMM 15m Option 673-2
Cable 3HAC030996-001 Adapter cable
Installation of internal harness (Euromap 67) in the Single Cabinet Controller

The following procedure details how to install the internal harness (Euromap 67) in the Single
Cabinet Controller.
1.
DANGER!
2.
esd
WARNING!
ESD! on page 29

Continued
3. Remove the original adapter plate on the front
of the controller.
xx0600002652
• A: original adapter plate

• B: attachment screw (8 pcs)
4. Fit the included adapter plate.
A B
xx0600002651
• A: Euromap adapter plate

5. Fit the harness through the connector hole on
the adapter plate, and fit the connector XS13
with the attachment screws.

xx0600002654
• A: connector XS13
6. Route the cables to I/O, fuse, relay and position See Location of Euromap harness in
switch terminal mounted on the cabinet door the Single Cabinet Controller on page
inside the cable protection according to the 123.
illustration.
7. Route the cables to the panel board connectors See illustration Location of Euromap
in the existing straps according to the illustra- harness in the Single Cabinet
tion. Controller on page 123.

Continued
8. Connect the connectors X1, X2 and X5 on the
panel board.
xx0500001890
9. Connect the wires no. 1002 and no. 1019 to the "Mould area free" (Euromap) or
light barrier and safety relay. "Enable Clamp motion" (SPI) signal.
This important signal tells the injection
moulding machine (IMM) that nothing
is inside it’s workarea.
This signal can be connected in
several different ways, position
switches, I/O based world zones, etc.
We recommend that it is to connected
to a safety relay, controlled by light
barriers.
10. Connect the wires to the additional fuse: See the location of the additional fuse
• wire no. 1032 to XT31.2 in Location of Euromap harness in the
• wire no. 1046 to XT31.4 Single Cabinet Controller on page
123.
11. Connect the wires between the additional fuse See the location of the add. fuse and
and I/O 1. I/O 1 in Location of Euromap harness
• wire no. 1053 from XT31.6 to X1.10 in the Single Cabinet Controller on
• wire no. 1055 from XT31.8 to X1.9 page 123.
12. Connect the wires to I/O 1. See the location of I/O 1 in Location of
• wire no. 1054 to X2.10 Euromap harness in the Single

• wire no. 1056 to X4.9 Cabinet Controller on page 123.
• wire no. 1057 to X1.9
• wire no. 1058 to X2.9
13. Fit the 24K1 and 24K2 relays on the mounting See Location of Euromap harness in
rail on the cabinet door. the Single Cabinet Controller on page
123.
14. Connect the connectors X1, X2, X3 and X4 on See location of I/O 2 in Location of
I/O 2. Euromap harness in the Single

Continued
Installation of internal harness (Euromap 67) in the Dual Cabinet Controller

The following procedure details how to install the internal harness (Euromap 67) in the Dual
Cabinet Controller.
1.
DANGER!
2.
esd
WARNING!
ESD! on page 29
3. Remove the original adapter plate on the front of
the controller.
xx0600002652
• A: original adapter plate

4. Fit the included adapter plate.
A B
xx0600002651
• A: Euromap adapter plate


Continued
5. Fit the harness through the connector hole on
the adapter plate, and fit the connector XS13
with the attachment screws.
xx0600002654
• A: connector XS13
6. Route the cables to the panel board connectors See the illustration inLocation of
in the existing straps according to the illustra- Euromap harness in the Dual Cabinet
tion. on page 124
7. Connect the connectors X1, X2 and X5 on the
panel board.
xx0500001890
8. Connect the wires no. 1002 and no. 1019 to the "Mould area free" (Euromap) or
light barrier and safety relay. "Enable Clamp motion" (SPI) signal.
This is a important signal that tells the
injection moulding machine (IMM)
that nothing is in its workarea.

This signal can be connected in
several ways.
Our recommendation is to connect it
to the light barrier and safety relay.
9. Connect the wires to the additional fuse: See the location of the additional fuse
• wire no. 1032 to XT31.2 in Location of Euromap harness in the
• wire no. 1046 to XT31.4 Dual Cabinet on page 124.
10. Connect the wires to I/O 1. See the location of I/O 1 in Location of
• wire no. 1053 to X1.10 Euromap harness in the Dual Cabinet
• wire no. 1054 to X2.10 on page 124.
• wire no. 1055 to X3.9
• wire no. 1056 to X4.9
• wire no. 1057 to X1.9
• wire no. 1058 to X2.9
11. Fit the 24K1 and 24K2 relays on the mounting See Location of Euromap harness in
rail on the cabinet door. the Dual Cabinet on page 124.

Continued
12. Connect the connectors X1, X2, X3 and X4 on See the location of I/O 2 in Location of
I/O 2. Euromap harness in the Dual Cabinet
on page 124.
Installation of the cable and converter box (Euromap 12)

The following procedure details how to install cable between the controller and the injection
moulding machines.
1. Connect the cable between converter box and the See Required equipment for
controller. Euromap 12 and SPI (Option no.
671-1) on page 125.
2. Connect the cable between the injection moulding See Required equipment for
machine and the converter box. Euromap 67 (Option no. 671-2) on
page 124.
3. Connect a 0V wire between the internal IMM power See
supply and pin 31 in the IMM connector.
WARNING!
To run the robot for commissioning without injection moulding machine, you have to jumper
the safety channel from the robot and spend 24V for the safety device relays (for Euromap
12). Use the included jumper plug (Harting connector).

2.9.8. Upgrading and installation of 2X Euromap interface (Option 671-4)
General
This section describes installation of 2X Euromap interface (Option 671-4) in an IRC5 Single
Cabinet Controller and in an IRC5 Dual Cabinet Controller. The customer option 2X
Euromap interface is not a pre mounted delivery option, it must be complimented with a
safety relay, not included in the option kit from ABB.
NOTE!
The 2X Euromap interface (Option 671-4) is an upgrade option and demands a pre installed
Euromap installation, described in section Installation of Euromap and SPI on page 123.
NOTE!
The harness used when installing 2X Euromap is identical with the pre mounted Euromap 1
harness. Beware of the identical connection markings.
Location of Euromap 2X interfaces in the Single Cabinet Controller

xx0800000214
A Connector A21.X5, on panel board

B Connector A21.X1, on panel board
C Connector A21.X2, on panel board
D Relay 24K1 and relay 24K2
E 2X Euromap 67: Digital 24 VDC I/O

Continued
F Cable protection
G Euromap adapter
H X13x and X14z connector
J Placement of customer safety relay
Location of Euromap 2X interfaces in the Dual Cabinet

xx0800000215
A Connector A21.X5, on panel board

B Connector A21.X1, on panel board
C Connector A21.X2, on panel board
D X13x and X14z connector
E 2X Euromap 67: Digital 24 VDC I/O
F XT31
G Connector XS13, relay 24K1 and relay 24K2
H Placement of customer safety relay

Continued
Required equipment for 2X Euromap interfaces in the Single Cabinet Controller

Cable harness 3HAC026692-001 Harness-Euromap 67 Single Cab.
DCC
Gasket 3HAC024175-001
Harness-Euromap 67 3HAC032370-001
adapter
Terminal block 3HAC17833-1
Marking card 3HAC17833-6
Standard tools
Required equipment for 2X Euromap interfaces in the Dual Cabinet

Cable harness 3HAC026821-001 Harness-Euromap 67 Dual Cab.
DCC
Gasket 3HAC024175-001
Harness-Euromap 67 3HAC032370-001
adapter
Terminal block 3HAC17833-1
Marking card 3HAC17833-6
Standard tools
Installation of interfaces in the Single Cabinet Controller
1.
DANGER!
Before any work inside the
cabinet, please observe the
DANGER - Make sure that
the main power has been
switched off! on page 28.
2.
esd
WARNING!
The unit is sensitive to ESD,
before handling the unit
please observe the safety
information in section
WARNING - The unit is
sensitive to ESD! on page 29
Continued
3. Before assembling the
harness 2, disconnect X31.1,
X31.2 and X31.3 and discard
the harness with the
connectors X1, X2 and X5 for
the panel board.
xx0800000218
4. Fit the harness 2 through the

connector hole on the adapter
plate, and fit the connector
XS14z with the attachment
screws.
xx0800000217
• A: Connector X14z
• B: Attachment screws
5. Disconnect the connectors
X13.1, X13.2 and X13.3 on
harness 1.

6. Use the adapter Described in section Adapter Euromap 67 on page 137.
3HAC032370-001 to connect
(harness 1 with harness 2)A
and the (panel board
harness)B, described in
section Adapter Euromap 67
on page 137
xx0800000220
7. Connect XP13.3 on harness 1 To complete the safety loop, described in section Wiring
to XS13.1 on harness 2. relay on page 138.

Continued
8. Connect the harness from the Connectors X13.1, X13.2 and X13.3, described in
panel board to the adapter. section Adapter Euromap 67 on page 137.
9. Connect the safety relay. Described in section Installation of safety relay on page
136.
Installation of interfaces in the Dual Cabinet
1.
DANGER!
DANGER - Make sure that the
main power has been switched
off! on page 28.
2.
esd
WARNING!
The unit is sensitive to ESD,
before handling the unit please
observe the safety information
in section WARNING - The unit
3. Install harness 2 and the Described in step 1-8 in section Installation of
adapter 3HAC032370-001. interfaces in the Single Cabinet Controller on page
133.
4. Connect the safety relay. Described in section Installation of safety relay on
page 136.
Requirements safety relay

The safety loop demands a safety relay, it is not included in the upgrade kit and has to be
supplied by the customer.
Relay specification:
• Two channels
• Six NO contacts

Continued
xx0800000213
NOTE!
To retain a full functional safety loop during a system power failure, it is important to use an
external power source for the customer safety relay.
Installation of safety relay
1.

DANGER!
page 28.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page
29
3. Assemble the relay (customer supplied) on the
recommended location in the IRC5 Controller.
4. Connect all wires from the adapter. Described in section Wiring
Relay.

Continued
Adapter Euromap 67
The figure below shoes the connections for the Euromap 67 adapter 3HAC032370-001.
xx0800000216
Wiring adapter
Harness Connection From-To Connection

1 XS13.1 X13-Adapter XP13.1
XP13.2 X13-Adapter XS13.2
XP13.3 X13-Adapter XS13.1 (X13 Harness 2)
XP13.1 A21-Adapter XS13.1
XS13.3 A21-Adapter XP13.3
2 XP13.2 X13-Adapter XS13.22
XP13.3 X13-Adapter XS13.32

Continued
Wiring relay
The figure below shoes the connections for the Euromap safety loop.
xx0800000219
Connection point A Connection point B

Wire No. Term Term
Designation Designation
1200 XS13.1 1 Safety relay 11
1201 2 21
1204 XP13.2 1 B1
1205 2 A1
1208 XS13.2 1 41
1209 2 31
1210 3 32
1211 4 42
1212 XP13.3 1 12
1213 2 22

1216 XS13.22 1 61
1217 2 51
1218 3 52
1219 4 62
1220 XS13.32 1 A2
1221 2 B2
1002 XT8:1 Socket
1019 XT8:3 Socket
1032 XT31 1 or 2
1046 XT31 5 or 6
1055 XT31 5 or 6

2.9.9. Installation of cooling fan harness axis 1 and 2
General
If the robot is going to be supplemented with cooling fans on axis 1 and 2 the controller has
to be supplemented with a internal harness.
Locations in Dual Cabinet Controller
xx0600002685
A Harness, cooling - Axis 1 and 2

B Cover with cable gland
C Contactor interface board
D Connector A43.X10
E Connector A43.X11

Continued
Locations in Single Cabinet Controller
xx0600002686
A Harness, cooling - Axis 1 and 2

B Cable protection
C Contactor interface board
D Connector A43.X10
E Connector A43.X11

F Position switch terminals
Required equipment
Equipment Article no. Note

Dual Cabinet Controller, Harness, 3HAC022723-001 7m
cooling - Axis 1 and 2 kit 3HAC022723-004 15m
3HAC022723-005 22m
3HAC022723-006 30m
Single Cabinet Controller, 3HAC025488-001
Harness, cooling - Axis 1 and 2 kit
Standard toolkit IRC5 See Standard toolkit, IRC5
on page 317.
Circuit diagram See Circuit Diagram on page
341.

Continued
Procedures for Dual Cabinet Controller

Following procedure details how to install the harness, cooling - Axis 1 and 2 kit in the Dual
Cabinet Controller.
1.
DANGER!
page 28.
2.
esd
WARNING!
29
3. Remove the cover plate to an empty slot on the
connection plate.
xx0500002688
• A: Sealing plug
• B: Cover plate with gasket
4. Route the harness through the empty slot. See Locations in Dual Cabinet
Controller on page 139.
5. Fit the cover with cable gland. See Locations in Dual Cabinet
6. Route the harness according to the illustration in
Locations in Dual Cabinet Controller on page 139

Continued
7. Connect the harness connectors to the contactor
interface board.
• A43.X11 to X11
• A43.X10 to X10
xx0500002690
See Locations in Dual Cabinet

Procedures for Single Cabinet Controller

Following procedure details how to install the harness, cooling - Axis 1 and 2 kit in the Single
Cabinet Controller.
1.
DANGER!
page 28.
2.
esd

WARNING!
29
3. Remove the two sealing plugs.
xx
• A: Sealing plug
• B: Cover plate with gasket
4. Fit the two connectors XS.8 and XS.58 from the See Locations in Single Cabinet
inside. Controller on page 140.

Continued
5. Route the cable to the left and connect the harness
connectors to the contactor interface board.
• A43.X11 to X11
• A43.X10 to X10
xx0500002690
See Locations in Single Cabinet

6. Route the wires with terminals to be mounted on the See Locations in Single Cabinet
cabinet door inside the cable protection according to Controller on page 140.
the illustration.
7. Fit the snap locking terminals to the plate on the
cabinet door according to the illustration.
xx0600002693
A. XT8/8.1
B. XT8/8.2
C. XP58.2
D. XP58.1
See Locations in Single Cabinet

2.9.10. Installation of Hot plug
Location
To be able to use the Hot plug function an additional hot plug button is needed. The figure
below shows the location of the hot plug button on the Single Cabinet Controller and Dual
Cabinet Controller.
xx0600002943
A Dual Cabinet Controller (Control Module)

B Dual Cabinet Controller (Drive Module)
C Single Cabinet Controller
D Hot plug button
Required equipment

Hot plug 3HAC026225-002 Single Cabinet Controller

Hot plug 3HAC026225-003 Dual Cabinet Controller
section Standard toolkit.
may be required. See references to the tools required.
references to these
Circuit diagram See Circuit Diagram on page 341.

Continued
Procedure Single Cabinet Controller

The procedure below details how to install the hot plug button in the Single Cabinet
Controller.
1.
DANGER!
2.
esd
WARNING!
connector for FlexPendant on the
computer unit.
xx0400000960
• A: Connector A32.A8
DSQC639:
xx0600002897

Continued
board unit.
xx0600002946
• A: Connector X10
5. Remove the FlexPendant connector with
harness from the Operator panel.
xx0600002948
• A: FlexPendant connector
6. Remove the plug that covers the hot plug
hole.
xx0600002949
• A: Plug
7. Fit the new FlexPendant connector and hot
plug button with harness into the empty
hole on the operator panel.
8. Connect the ethernet connector for
FlexPendant to the computer unit.
9. Connect the signal connector A21.X10 to

Continued
10. Connect the cables to the hot plug button
connector.
xx0600002953
11. Place the warning label above the hot plug

button.
xx0600002957
• A: Warning label
12. Test the hot plug button function. See section Test of hot plug button function
on page 150.

Continued
Procedure Dual Cabinet Controller

The procedure below details how to install the hot plug button in the Dual Cabinet Controller.
1.
DANGER!
2.
esd
WARNING!
connector for FlexPendant on the computer
unit.
xx0400000960
• A: Connector A32.A8
DSQC639:
xx0600002897

Continued
board unit.
xx0600002946
• A: Connector X10
5. Remove the cover plate with the
FlexPendant connector and harness.
xx0600002954
• A: Cover plate
6. Fit the new cover plate with FlexPendant
connector and hot plug button with harness
into the empty slot.
7. Connect the ethernet connector for
FlexPendant to the computer unit.

8. Connect the signal connector A21.X10 to

Continued
9. Connect the cables to the hot plug button
connector.
xx0600002956
10. Place the warning label below the hot plug

button.

xx0600002955
• A: Warning label
11. Test the hot plug button function. See section Test of hot plug button
function on page 150.
Test of hot plug button function

The procedure below details how to test the hot plug button function.
1. Make sure that the system is in automatic mode.
2. Press the motors on button.
3. Press and hold the hot plug button.
• Verify that the red lamp indicates when
actuated.
• Verify that the system still has motors on.

Continued
4. Keep pressing the hot plug button and at the same
time, switch the jumper plug with the FlexPendant
plug.
5. Release the hot plug button. Make sure that the button is not
• Verify that the system still has motors on. stuck in the actuated position
since it disables the FlexPendant
emergency stop button.
6. Press and hold the hot plug button.
7. Keep pressing the hot plug button and at the same
time, switch the Flexpendant plug with the jumper
plug.
8. Release the hot plug button.
• Verify that the FlexPendant starts up
correctly.
9. Switch to Manual mode. Motors off
10. Confirm the mode change.
• Verify motors on.
11. Press the hot plug button.
• Verify motors off.

2.9.11. Installing the EPS board DSQC 646 for Electronic Position Switches
General
To use the option Electronic Position Switches you need to install an EPS board in the robot
controller. The procedure below will show how to install this board.
NOTE!
It is not possible to have the options EPS and SafeMove installed at the same time - that is,
only one of these two options can be installed and used.
WARNING!
The safety controller has passive monitoring, i.e. it does not stop the robot. If an axis is
outside its configured range, an output signal goes low. It is the responsibility of the
installation personnel to connect the output signals in such a way that the robot is stopped if
there is a risk of a dangerous situation.
Illustration
The EPS board should be mounted behind the axis computer.
xx0600003203
A EPS board
B Axis computer

Continued
Procedure
The procedure below details how to install an EPS board.
1.
DANGER!
2.
esd
WARNING!
3. If not already in place, fit the EMC strips on
the EPS board. A
xx0700000087
4. Connect the short SMB cable and both

Ethernet cables to the EPS board before
mounting the board. These connections
may be difficult to reach once the board is
mounted.
The two Ethernet connectors on the EPS
board are interchangeable (it does not
matter which is connected to the main
computer and which is connected to the
axis computer).
xx0600003303

Continued
5. Remove the attachment screws of the axis
computer. A
B B
xx0500002002
6. Lift out the axis computer so that the EPS
board can be fitted behind the axis
computer.
7. Fit the EPS board in the same place as the
axis computer was before.
A
B B

xx0600003204
• A: EPS board

Continued
8. Fit the axis computer on the EPS board.
xx0600003206
• B: EPS board
• C: attachment screws
9. For a Single Cabinet Controller: Remove
the Ethernet cable between the main
computer and the axis computer. Replace it
with the long Ethernet cable from the EPS
board to the main computer. Connect the
short Ethernet cable between the EPS
board and the axis computer.
For a Drive Module: Remove the existing

Ethernet cable from the axis computer and
connect it to the EPS board. Connect the
short Ethernet cable between the EPS
xx0600003218

Continued
10. Remove the SMB cable from the axis
computer and connect it to the EPS board.
Connect the SMB cable from the EPS board
to the axis computer.
xx0600003207
11. Remove the power cable from the axis

computer and connect it to the split cable.
Connect the split cable to the EPS board
and the axis computer.
xx0600003208

Continued
12. Connect signal cables to the plug contact,
which is then connected to the I/O
connector of the EPS board.
• Connect a power supply, 24 V to pin
1 and 0 V to pin 2. Check with a
voltmeter that the voltage is 24 V
between pin 1 and 2 on the Phoenix
connector.
• Connect the output signals from the
EPS board (pin 3-12).
• Connect the sync switch signals to
pin 13 and 14. If dual channel wiring
is not used, connect only pin 14.
xx0600003209
• A: I/O Connector
• B: Plug contact
• C: Power supply
• D: 5 safe outputs (10 signals)
• E: Sync switch (dual signal)

2.9.12. Installing the SafeMove board DSQC 647
General
To use the option SafeMove you need to install an SafeMove board DSQC 647 in the robot
controller. The procedure below will show how to install this board.
NOTE!
It is not possible to have the options SafeMove and EPS installed at the same time - that is,
only one of these two options can be installed and used.
Location
The SafeMove board should be mounted behind the axis computer.
xx0800000102
A SafeMove board
B Axis computer

Continued
Procedure
The procedure below details how to install the SafeMove board.
1.
DANGER!
2. WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety
information in section Warning - The unit is
sensitive to ESD! on page 27.
the SafeMove board.
A
xx0800000204
• A: EMC strips

Continued
4. Connect both SMB cables and both Ethernet
cables to the SafeMove board before
mounting the board. These connections may
be difficult to reach once the board is
mounted.
The two Ethernet connectors on the
SafeMove board are interchangeable (it
does not matter which is connected to the
main computer and which is connected to
the axis computer).
xx0800000103
• A: SMB1 cable
• B: SMB2 cable
• C: Ethernet cables
computer.
A
B B
xx0500002002
• B: attachment screws (4 pcs)
6. Lift out the axis computer so that the
SafeMove board can be fitted behind the
axis computer.

Continued
7. Fit the SafeMove board in the same place as
the axis computer was before. A
B
B
xx0800000104
• A: SafeMove board
• B: attachments screws (4 pcs)
8. Fit the axis computer on the SafeMove
board.
xx0800000017
• A: Axis computer
• B: SafeMove board
• C: attachment screws (4 pcs)

Continued
9. For a Single Cabinet Controller: Remove
the Ethernet cable between the main
computer and the axis computer. Replace it
with the long Ethernet cable from the
SafeMove board to the main computer.
Connect the short Ethernet cable between
the SafeMove board and the axis computer.
For a Dual Cabinet Controller, Drive Module:

Disconnect the Ethernet cable from the axis
computer and connect it to the SafeMove
board. Connect the short Ethernet cable
between the SafeMove board and the axis
computer.
xx0800000018
10. Disconnect the SMB cables from the axis

computer and connect them to the
SafeMove board.
xx0800000031
• A: SMB1 cable (robot)

• B: SMB2 cable (external axes)

Continued
11. Connect the SMB cables from the SafeMove
board to the axis computer
xx0800000032
• A: SMB1 cable
• B: SMB2 cable
12. Disconnect the power cable from the axis
computer and connect it to the split cable.
Connect the split cable to the SafeMove
xx0800000028

Continued
13. Connect the limit switch cable between the SafeMove board:
SafeMove board (X13) and the contactor
interface board (X21)
xx0800000033
Contactor interface board:
A
xx0800000105
• A: limit switch cable

14. Mount the plugs in the limit switch override The limit switch override contact must be
contact (X23) at pin 1 and 4 on the contactor plugged and not used when using
interface board. SafeMove.
xx0800000035
• A: plug (2pcs)

Continued
15. Connect signal cables to the plug contacts,
which is then connected to the I/O connector
of the SafeMove board.
xx0700000640
• A: Power supply
• B: 8 safe outputs (16 signals)
• C: 8 safe inputs (16 signals)
• D: Sync switch (dual signal)
• E: Override operation input (dual
signal)

2.9.13. Installation of Remote Service
General
To use the option Remote Service you need a Remote Service box mounted in the robot
controller. The procedure below will show how to connect the Remote Service antenna.
Location
The illustration below shows the Remote Service box in the Single Cabinet Controller.
For Dual Cabinet Controller the Remote Service box is located on the botton in the Control
Module.
xx0800000094
A Remote Service box

Continued
Procedure
The following procedure details how to connect the Remote Service antenna.
1. Connect the antenna cable to the adapter
cover plate on the controller.
Use tightening torque 0.8 - 1.1 Nm.
xx0800000095
• A: Antenna connector
2. Place the antenna on top of the controller.


3 Maintenance activities, controller IRC5
3.1. Maintenance schedule, controller IRC5

3.1. Maintenance schedule, controller IRC5
General
The IRC5 robot controller must be maintained at regular intervals to ensure its function. The
maintenance activities and their respective intervals are specified below:
Intervals
Maintenance Detailed in
Equipment Interval Note!
activity section:
Complete Inspection 12 months * Inspection of the
controller modules controller on
page 170.
Moist dust filter Cleaning Cleaning moist
dust filter on
page 177
Moist dust filter Replacement 24 months * Replacement of
moist dust filter
on page 173
Heat exchanger Inspection 6 months * Inspection of the
fan controller on
page 170.
Heat exchanger Cleaning 12 months * Cleaning of the
fan IRC5 controller
on page 176.
Drive system fans Inspection 6 months * Inspection of the
controller on
page 170.
Drive system fans Cleaning 12 months Cleaning of the
IRC5 controller
on page 176.
FlexPendant Cleaning When needed Cleaning the

FlexPendant on
page 179.
Earth Fault Testing 6 months Contact ABB for
Breaker more information
*) The time interval depends on the working environment of the equipment: a cleaner
environment may extend the maintenance interval and vice versa.

3.2.1. Inspection of the controller
3.2 Inspection activities
Inspection
The procedure below details how to inspect the IRC5 controller.
WARNING!
Please observe the following before commencing any repair work on the IRC5 Controller
modules or units connected to the controller:
• Switch off all electric power supplies with the power switches on the Control and
Drive modules!
• Before handling, make sure you are grounded through a special ESD wrist bracelet or
similar. Many components inside the module are sensitive to ESD (ElectroStatic
Discharge) and can be destroyed if exposed to discharge. See the Safety chapter,
WARNING - The unit is sensitive to ESD! on page 29
1. Inspect all sealing joints and cable
glands to make sure they are airtight in
order to prevent dust and dirt from
penetrating into the controller.
2. Inspect connectors and cabling to
make sure they are securely fastened
and cabling not damaged.
3. Inspect the heat exchanger andthe fan
on the controller to make sure it is
clean.
xx0500001952
Parts:
• A: fan
• B: heat exchanger
• C: top cover
• D: attachment screw (4 pcs)

Continued
4. Inspect the drive system fans and air
channels in the controller to make sure
they are clean.
xx0500002172
• A: drive system fans (4 pcs)

5. After cleaning: Replace any malfunctioning fans as detailed in
Temporarily turn the power supply to theReplacement of heat exchange unit and fan
the modules on. on page 218orReplacement of drive system
Inspect all fans to make sure they fans on page 300.
function correctly.
Turn the power supply back off.

3.3.1. Activities
3.3 Changing/replacing activities
3.3.1. Activities
References
Certain activities to be performed as specified in the Maintenance Schedule are not all
detailed in this chapter, but in the Repairs chapter.
Please refer to the Repair chapter of the equipment in question.

3.3.2. Replacement of moist dust filter
Location
The moist dust filters are located as shown in the illustration below.
xx0700000128
A Moist dust filter magazine

B Single Cabinet Controller
C Dual Cabinet Controller, Control Module
D Dual Cabinet Controller, Drive Module
Required equipment
Equipment Note
Moist dust filter

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

Continued
Removal
The procedure below details how to replace the moist dust filter.
1. Pull the moist dust filter magazine upwards.
xx0700000131
2. Pull the moist dust filter magazine in the arrow

direction and remove it.

xx0700000132
3. Remove the old moist dust filter by releasing

the lock shackle and lifting it.
xx0200000003

Continued
Refitting
The procedure below details how to refit the moist dust filter.
1. Fit the new moist dust filter in the magazine and
lock it with the lock shackle.
NOTE!
The compact surface on the moist dust filter
must be turned inwards to the cabinet.
2. Fit the moist dust filter magazine on the cabinet
and push inwards.
xx0700000134
3. Push the moist dust filter magazine downwards

until it stops.
xx0700000135

3.4.1. Cleaning of the IRC5 controller
3.4 Cleaning activities
3.4.1. Cleaning of the IRC5 controller
Required equipment
Equipment, etc. Note

Vacuum cleaner ESD Protected
Cleaning agent, exterior cleaning If necessary, use rag with e.g. alcohol
Internal cleaning
The procedure below details how to clean the interior of theControl and Drive Module
1. Clean the cabinet interior with a vacuum cleaner if
necessary.
2. The control module is equipped with a heat If required, remove any heat
exchanger, it is important that it is clean. exchangers before cleaning as
The heat exchanger is found: detailed in the section,
• on the rear of the controller. Replacement of heat exchange
unit and fan on page 218.
3. The controller is equiped with air channels. To clean How to remove the fans is
the channels: detailed in section,
• Remove the drive module fans and use Replacement of drive system
compressed air to clean the channels. fans on page 300.
4. If the IRC5 controller is installed in a very harsh envi- How to remove the drive units is
ronment, the drive units cooling fans must be cleaned detailed in section,
at regular intervals. Replacement of servo drive
units, rectifierand capacitorunit
on page 279
Do's and don'ts!

The section below specifies some special considerations when cleaning the controller.
Always:
• use ESD Protection
• use cleaning equipment as specified above! Any other cleaning equipment may
shorten the life of paintwork, rust inhibitors, signs, or labels!
• check that all protective covers are fitted to the controller before cleaning!
Never:
• remove any covers or other protective devices when cleaning the outside of the
controller!
• use compressed air or spray with a high pressure cleaner!
• leave the door open when cleaning exterior

3.4.2. Cleaning moist dust filter
Location
The moist dust filters are located as shown in the illustration below.
xx0700000128
A Moist dust filter magazine

B Single Cabinet Controller
C Dual Cabinet Controller, Control Module
D Dual Cabinet Controller, Drive Module
Required equipment
Equipment Note
Cleaning agent Water 30-40°C with cleansing liquid or detergent.
Compressed air
Cleaning
The procedure below details how to clean the moist dust filter.
1. Remove the moist dust filter. How to remove the moist dust
filter is detailed in section
Replacement of moist dust filter
on page 173.
2. Clean the filter three or four times.
3. Allow the filter to dry in one of these ways: Do not wring the filter out!
• Lying flat on a flat surface
• Blow with compressed air in opposite
direction of filter airflow.

Continued
4. Refit the moist dust filter. How to refit the moist dust filter is
detailed in section Replacement
of moist dust filter on page 173.

3.4.3. Cleaning the FlexPendant
Location
The surfaces to clean are shown in the illustration below.
xx0400000973
A Touch screen
B Hard buttons
Required equipment
Equipment, etc. Note

Soft cloth ESD Protected
Warm water/Mild cleaning agent
Clean the touch screen

This section details how to clean the touch screen.
1. Before cleaning the screen, tap
the Lock Screen on the ABB
menu.
en0400001221

Continued
2. Tap the Lock button in the
following window.
en0400000657
3. When the next window appers, it is

safe to clean the screen.
en0400000658
4. Clean the touch screen and

hardware buttons using a soft
cloth and water or a mild cleaning
agent.

5. To unlock the screen, follow the
intructions on the screen.
en0400000658

Continued
Do's and don'ts!

The section below specifies some special considerations when cleaning the FlexPendant.
Always:
• use ESD Protection
• use cleaning equipment as specified above! Any other cleaning equipment may
shorten the life time of the touch screen.
• check that all protective covers are fitted to the device before cleaning!
• make sure that no foreign objects or liquids can penetrate into the device.
Never:
• remove any covers before cleaning the FlexPendant!
• spray with a high pressure cleaner!
• clean the device, operating panel and operating elements with compressed air,
solvents, scouring agent or scrubbing sponges.


4 Repair activities, controller IRC5
4.1. Overview

4.1. Overview
General
The ABB IRC5 controller is available in two basic configurations: Single Cabinet Controller
and Dual Cabinet Controller.
xx0600002929
A Dual Cabinet (Control Module)

B Dual Cabinet (Drive Module)
C Single Cabinet
The Single Cabinet Controller has all components in one single cabinet and the Dual divides
the components into two modules: Control Module and Drive Module.
The Single Cabinet Controller is regarded as the standard configuration and therefor the
illustration in the procedures detailed in this manual are based on the Single Cabinet
Controller.
If the procedure in general is the same, it is mentioned in each procedure where the part is
located in the Dual Cabinet configuration. If there are significant differences, both cabinet
configurations are shown.
NOTE!
When replacing a unit in the controller, report to ABB:
• the serial number
• articel number
• revision
of both the replaced unit and the replacement unit.
This is particularly important for the safety equipment to maintain the safety integrety of the
installation.

4.2. Replacement of panel board
Location
The panel board unit is located as shown in the illustration below.
In the Dual Cabinet Controller the panel board unit is located in the Control Module.
xx0400000811
B Capacitor
C Computer unit

D Panel board unit
E Axis computer
Required equipment
Equipment Note
Panel board unit DSQC643
See Controller system parts on page 321
toolkit!

Continued
Removal
The procedure below details how to remove the panel board unit.
1.
DANGER!
page 28.
2.
esd
WARNING!
section WARNING - The unit is sensitive to ESD!
on page 29
3. Disconnect all connectors. Note
Make a note of any connections.
4. Remove the lower attachment screw, and remove
the Panel Unit.
xx0400000812
• A: fixed attachments
• B: hole for attachment
screw

Continued
Refitting
The procedure below details how to refit the panel board unit.
1.
DANGER!
page 28.
2.
esd
WARNING!
3. Refit the panel board unit.
4. Refit the lower attachment screw.

xx0400000812
• A: fixed attachments
• B: hole for attachment
screw
5. Reconnect all connectors.

4.3.1. Replacement of control power supply
4.3 Replacement of power supply
Location
The control power supply is located on the left hand side as shown in the illustration below.
For the Dual Cabinet Controller the control power supply is located in the Control Module
with the same placement.
xx0400000815

B Contactors
C Drive unit power supply

Required equipment
Equipment Spare part no. Art. no. Note

Control Power Supply 3HAC12928-1 DSQC 604
Standard toolkit The contents are
defined in section
Standard toolkit!
Other tools and These procedures
procedures may be include references to
required. See the tools required.
references to these
procedures in the step-
by-step instructions
below.

Continued

Circuit Diagram 3HAC024480-004 Complete control
system
Removal
The procedures below details how to remove the control power supply.
1.
DANGER!
2. Disconnect the connectors X1 - X4 on the
control power supply.
3. Loosen the attachment screw and pull the
power supply down to release it from the cap
nut.
xx04000000976
• A: cap nut

4. Remove the power supply unit.
Refitting
The procedures below details how to refit the control power supply.
1.
DANGER!
Before any work inside the cabinet, please observe the
safety information in section DANGER - Make sure that
the main power has been switched off! on page 28.

Continued
2. Refit the new power supply unit by pushing it upward to
fit the cap nut.
Refit the control power supply by pull it down to fit the
cap nut.
xx04000000976
• A: cap nut
3. Lock the unit in place by tighten the attachment screw.
4. Reconnect the connectors X1 - X4.
5. Refit the front with the Panel Board Unit.

4.3.2. Replacement of power distribution board
General
In the Single Cabinet Controller the control power supply DSQC 604 will be replaced by the
power distribution board DSQC 662. The replacement will start from August 2007.
Location
The power distribution board is located on the left side as shown in the illustration below.
xx0700000139
A Customer I/O power supply

B Power distribution board
C System power supply
CAUTION!
Hot surface on top of the power distribution board unit.
Risk of burns. Be carefull when removing the unit.
Do not route or place cables on top of the power distribution board.
Required equipment

Power distribution board 3HAC026254-001 DSQC 662
defined in section
Standard toolkit.

Continued

Other tools and procedures
may be required. See
references to these
Circuit diagram 3HAC024480-004
Removal
The procedure below details how to remove the power distribution board.
1.
DANGER!
2.
CAUTION!
Hot surface on top of the power distribu-
tion board unit.
Risk of burns. Be carefull when removing
the unit.
3. Disconnect the connectors X1 - X9 on the
power distribution board.
4. Loosen the left attachment screw, remove
the right attachment screw and pull the
power distribution board rightward to
release it from the left screw head.
xx070000122
• A: left attachment screw

• B: right attachment screw
5. Remove the power distribution board.

Continued
Refitting
The procedure below details how to refit the power distribution board.
1.
DANGER!
2. Refit the new power distribution board by
pushing it leftward to fit the left screw
head.
Refit the right screw.
xx070000122
• A: left attachment screw

• B: right attachment screw
3. Lock the unit in place by tighten the
attachment screws.
4. Reconnect the connectors X1 - X9.
CAUTION!
Hot surface on top of the power distribu-
tion board unit.
Do not route or place cables on top of the
power distribution board.

4.3.3. Replacement of customer I/O power supply, IRC5
Location
The customer I/O power supply is located as shown in the illustration below. For the Dual
Cabinet Controller the customer I/O power supply is located in the Control Module with the
same placement.
xx0500001951

B Contactors

Required equipment

Customer I/O Power 3HAC12934-1 DSQC 608
Supply
defined in section
Standard toolkit!
Other tools and These procedures
procedures may be include references to
required. See the tools required.
references to these
procedures in the step-
by-step instructions
below.

Continued

system
Removal
The procedure below details how to remove the customer I/O power supply.
1.
DANGER!
2. Remove the Flage disconnect unit. (option) Detailed in section
Replacement of Flange
disconnect on page 205
3. Disconnect all connectors. NOTE!
Make a note of any connec-
tions.
4. Remove the upper and lower attachment screws.
xx0400000908
• A: attachment screw
(2 pcs)

Continued
Refitting
The procedure below details how to refit the customer I/O power supply.
1.
DANGER!
2. Refit the new power supply unit.
3. Refit the attachment screws.
xx0400000908
(2pcs)
5. Refit the Flange disconnect unit (option). Detailed in section
Replacement of Flange
disconnect on page 205

4.3.4. Replacement of customer I/O power supply
General
In the Single Cabinet Controller and Dual Cabinet Controller the customer I/O power supply
DSQC 608 will be replaced by the customer I/O power supply DSQC 609. The replacement
will start from August 2007.
Location
The customer I/O power supply is located as shown in the figure below. For the Dual Cabinet
Controller the customer I/O power supply is located in the Control Module with the same
placement.

xx0700000139

CAUTION!
If there are two or more Customer I/O power supply units mounted in a row and too close to
each other, there will be a heating problem and the units can be damaged.
To avoid damaging the Customer I/O power supply units, the units must be separated with 3
pcs of exterior support.
Required equipment

Customer I/O power supply 3HAC14178-1 DSQC 609

Continued

defined in section
Standard toolkit.
Other tools and procedures These procedures
may be required. See include references to
references to these the tools required.
Circuit diagram. 3HAC024480-004
Removal
The procedure below details how to remove the customer I/O power supply.
1.
DANGER!
page 28.
2. Remove the Flange disconnect unit (option). Detailed in section Replacement
of Flange disconnect on page 205
3. Loosen the terminal screws for each connected
wire. Remove wires from the terminals.
4. Loosen the DIN-lock fixing screw.
xx070000124
• A: DIN-lock fixing screw

• B: DIN-lock lever
5. Pull the DIN-lock lever downwards to release the
power supply unit.

Continued
Refitting
The procedure below details how to refit the customer I/O power supply.
1.
DANGER!
page 28.
2. Refit the new power supply unit on the DIN-rail.
3. Fasten the DIN-lock fixing screw.
xx0700000124
• A: DIN-lock fixing screw

• B: DIN-lock lever
4. Refit all wires in the screw terminals.
5. Fasten the screw terminal screws with correct © Copyright 2004-2008 ABB. All rights reserved.
torque.
6. Refit the Flange disconnect unit (option). Detailed in section Replacement
of Flange disconnect on page
205.

4.3.5. Replacement of drive system power supply
Location
The illustration below shows the location of the drive system power supply in a Single
Cabinet Controller.
In the Dual Cabinet Controller the drive system power supply is located in the Drive Module.
xx0400000998

B Contactor

Required equipment

Drive system power supply 3HAC026289-001 DSQC 626A
Drive system power supply 3HAC020466-001 DSQC 627
defined in section
Standard toolkit!
Other tools and procedures These procedures
may be required. See include references
references to these to the tools
procedures in the step-by- required.

Continued

system
Removal
The procedure below details how to remove the drive system power supply.
1.
DANGER!
2. Disconnect all connectors from the unit.
A

xx0500001842
• A: drive system power supply

• B: cup nut (2 pcs)
• C: attachment screw (2 pcs)
3. Loosen the attachment screws.
4. Pull the power supply unit to the right to
release it from the cap nuts, and remove it.

Continued
Refitting
The procedure below details how to refit the drive system power supply.
1.
Danger
DANGER!
Before any repair work, please observe the
safety information in section DANGER - Make
sure that the main power has been switched
off!.
2. Refit the power supply by sliding the recesess
in beneath the cap nuts, and push it to the left.
A
xx0500001842
• A: drive system power supply

• B: cup nut (2 pcs)

3. Tighten the attachment screws.
4. Reconnect all connectors to the unit .

4.3.6. Replacement of system power supply
General
In the Single Cabinet Controller the drive system power supply DSQC 626A/627 will be
replaced by the system power supply DSQC 661.The replacement will start from August
2007.
Location
The illustration below shows the location of the system power supply in the Single Cabinet
Controller.

xx0700000139

Required equipment

System power supply 3HAC026253-001 DSQC 661
defined in section
Standard toolkit.
Other tools and procedures
may be required. See
references to these
Circuit diagram 3HAC024480-004
Continued
Removal
The procedure below details how to remove the system power supply.
1.
DANGER!
page 28.
2. Disconnect all connectors from the unit.
3. Loosen the two lower attachment screws.
xx0700000125
• A: upper attachment
screws
• B: lower attachment
screws
4. Remove the two upper attachment screws.
5. Pull the power supply unit outwards and then
upwards to release it from the lower screw heads,
and remove it.

Continued
Refitting
The procedure below details how to refit the system power supply.
1.
DANGER!
page 28.
2. Refit the power supply by sliding the recesses in
beneath the lower screw heads, and push it inwards
and the downwards.
xx0700000125
• A: upper attachment
screws

• B: lower attachment
screws
3. Refit the two upper attachment screws.
4. Tighten the attachment screws (4 pcs).
5. Reconnect all connectors to the unit.

4.4. Replacement of Flange disconnect
Location
The Flange disconnect unit is located as shown in the illustration below.
xx0600003133
A Flange disconnect
Required equipment

Flange disconnect 3HAC027113-001

may be required. See references to the tools needed.
references to these
341.

Continued
Removal
The procedure below details how to remove the Flange disconnect unit.
1.
DANGER!
2. Remove the link by pushing the spring forward.
WARNING!
Be careful when removing the link. The link is
spring-loaded and the spring can with high force
pull the link down when it is released.
xx0600003141
• A: spring
• B: link
3. Remove the two lower attachment screws.
xx0600003139
• A: attachment screws

Continued
4. Loosen the two upper attachment screws and
remove the unit.
xx0600003140
5. Disconnect the cables.
Refitting
The procedure below details how to refit the Flange disconnect unit.
1.
DANGER!
page 28.
2. Reconnect the cables.
3. Refit the unit and fasten the two upper attachment

screws.
4. Refit the two lower attachment screws.
5. Refit the link to the unit.

4.5. Replacement of I/O units and Gateways
General
A number of I/O units and Gateways may be installed in the IRC5 controller. These are
specified in Definition of I/O units, IRC5 on page 100.
How to configure the I/O units is detailed in Operating-manual Robot Studio.
Location in Single Cabinet Controller

The location of I/O units, Gateways or encoder interface units in the Single Cabinet
Controller is shown in the illustration below.
xx0500001859
A Gateway, I/O Units or encoder interface units

B Mounting rail
Location in Dual Cabinet Controller

The location of I/O units, Gateways or encoder interface units in the Dual Cabinet Controller
is shown in the illustration below.
xx0600002684
A Gateway, I/O Units or encoder interface units

Continued
Required equipment
Equipment Note
A number of choices are available! Specified in section Definition of I/O units,
IRC5 on page 100.
toolkit!
Circuit Diagram See Circuit Diagram on page 341.
Removal
The procedure below details how to remove the I/O units or Gateways.
1.
DANGER!
2.
esd
WARNING!
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 29
3. Identify the I/O unit or Gateway to be replaced.

4. Disconnect the connectors from the unit. Note which connector goes where, to
facilitate reassembly.
5. Tip the unit away from the mounting rail and
remove it.
Refitting
The procedure below details how to refit the I/O units or Gateways.
1.
DANGER!

Continued
2.
esd
WARNING!
3. Hook the unit back onto the mounting rail and snap it
gently in position.
4. Reconnect all connectors disconnected during removal.

4.6. Replacement of backup energy bank
Location
The illustration below shows the location of the backup energy bank in a Single Cabinet
Controller.
In the Dual Cabinet Controller the backup energy bank is located in the Drive Module.
xx0500001951

B Contactor
Required equipment
Equipment Note
Backup energy bank DSQC 655 with or without adapter plate.
See Controller system parts on page 321.
toolkit!

Continued
Removal
The procedure below details how to remove the backup energy bank.
1.
DANGER!
2. Disconnect the connector X4 from the control
power supply.
C
B D
A
E
xx0600002900
• A: connector
• B: cup nut
• C: control power supply
• D: backup energy bank
• E: attachment screw
3. Remove the attachment screw.
4. Pull the backup energy bank out.
Refitting © Copyright 2004-2008 ABB. All rights reserved.

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

Continued
2. Refit the new backup energy bank.
B D
A
E
xx0600002900
• A: connector
• B: cup nut
• C: control power supply
• D: backup energy bank
• E: attachment screw
3. Refit the attachment screw, and tighten it.
xx0600003231
• A: Backup energy bank

• B: connector
• C: attachment screws
4. Reconnect the connector to the control

power supply connector X4.


4.7. Replacement of control system fan
Location
The control system fan is located in the back of the Single Cabinet Controller as shown below.
On the Dual Cabinet Controller the control system fan is located on the Control Module.
xx070000416
A Fan
B Top cover
C Attachment screws (4 pcs) © Copyright 2004-2008 ABB. All rights reserved.
Required equipment
Equipment Note
Fan with receptacle See Miscellaneous parts on page 326.
toolkit, IRC5 on page 317
Other tools and procedures may be required.
See references to these procedures in the

Continued
Removal of control system fan

The procedure below details how to remove the control system fan.
1.
DANGER!
DANGER - Make sure that the
main power has been switched
off! on page 28.
2. Remove the attachment screws
on the top cover.
xx0700000416
• A: fan
• B: top cover
3. Remove the top cover.
4. Disconnect the connector to the
fan.
5. Remove the screw (item B in
image below).

Continued
6. Push the fan upwards, and pull
it out.
xx0700000417
• A: fan
• B: screw
Refitting of control system fan

The procedure below details how to refit the control system fan.
1. Put the fan in place, and push
it down.
xx0700000417
• A: fan
• B: screw
2. Refit the screw (item B in
image above).
3. Reconnect the connector to
the fan.

Continued
4. Refit the top cover.
xx0700000416
• A: fan
• B: top cover

4.8. Replacement of heat exchange unit and fan
Location
The heat exchanger unit is located in the back of the Control Module as shown below. On the
Dual Cabinet Controller the heat exchange unit is located on the Control Module.
xx0500001952
A Fan
B Heat exchanger
C Top cover
D Attachment screws (4 pcs)
Required equipment
Equipment Spare part no. Note

Fan with receptacle 3HAC021700-001 Room temp MAX52°C

IRB 6600, IRB 7600 IRB 660 and
IRB 6620
Fan with receptacle 3HAC021702-001 Room temp (MAX45°C) or Room
temp (MAX52°C)
IRB 140, IRB 340 IRB 1400,
IRB 2400, IRB 4400 and
IRB 1600
Heat exchange unit 3HAC024439-001 Room temp MAX52°C
Adhesive Product name, Casco S55
section Standard toolkit, IRC5 on
page 317.
be required. See references to references to the tools required.

Continued
Removal of heat exchanger fan

The procedure below details how to remove the heat exchange unit fan.
1.
DANGER!
2. Remove the attachment screw on the top
cover.
xx0500001952
• A: fan
• A: heat exchanger
• C: top cover
3. Remove the top cover. Shown in the figure above.
4. Disconnect the connector to the fan.
5. Remove the screw (item B in image below).
6. Push the fan upwards, and pull it out.
xx0500001954
• A: fan
• B: screw

Continued
Refitting of heat exchanger fan

The procedure below details how to refit the heat exchange unit fan.
1. Put the new fan in place, and push down.
xx0500001954
• A: fan
• B: screw
2. Refit the screw (item B in image above).
3. Reconnect the connector to fan.
4. Refit the top cover.
xx0500001952
• A: fan
• B: heat exchanger © Copyright 2004-2008 ABB. All rights reserved.
• C: top cover
5. Refit the attachment screws Shown in the figure above.
Replacement of heat exchange unit

The procedure below details how to remove the heat exchange unit.
1.
DANGER!

Continued
2. Follow step 2 through 5 in Removal of heat
exchanger fan on page 219.
3. Mark the placement of the heat exchange unit
with a pen before removal.
4. Use a chisel and a hammer to wedge between
the heat exchange unit and cabinet wall in all
A
four coners of the heat exchanger.
B
xx0600002677
• A: chisel
• B: heat exchange unit
5. Remove the exchanger unit.
6. Apply the adhesive on a cleaned and dry
surface on the new heat exchanger unit. A
B
xx0600002678
• A: heat exchange unit

• B: adhesive run
7. Fit the new heat exchange unit within 20min. It
could be necessary to fixate the unit in position
until the adhesive is hard.
8. Follow the step 1 to 4 in Refitting of heat
exchanger fan on page 220.

4.9. Replacement of computer unit DSQC623
Location
The computer unit is located in the top of the module as shown below.
In the Dual Cabinet Controller the computer unit is located in the Control Module.
xx0500001858
Pos Description
B Capacitor
C Computer unit
D Panel unit
E Axis computer

F Drive system, (drive units and rectifier)
Required equipment
Equipment Note
Computer unit AC plus Includes IDE flash
324.
Computer unit BD plus Includes hard disk drive
324.
toolkit!
required. See references to these tools required.
below.
Continued
Removal
The procedures below details how to remove the computer.
1.
DANGER!
2.
esd
WARNING!
on page 29
3. Disconnect all connectors from the computer NOTE!
unit. Make a note of any connections.
4. Push the spring lock to the right
xx0500001956
Parts:
• A: spring lock
• B: computer unit

Continued
5. Pull the computer unit out until the guide pins
reach the end stop.
xx0500001957
Parts:
• A: guide pin at end stop
6. Let the front end of the computer unit down, and
lift guide pins over the end stop.
xx0500001958
Refitting
The procedure below details how to refit the computer unit.
Action Note/illustration © Copyright 2004-2008 ABB. All rights reserved.
1.
DANGER!
2.
esd
WARNING!
on page 29
Continued
3. Place the rear guide pins of the computer unit
over the end stops.
xx0500001984
Parts:
• A: end stop
• B: guide pin
4. Lift the front end of the computer unit up.
xx0500001985
5. Push the computer unit in until the spring lock

snaps in position.
xx0500001986
Parts:
• A: spring lock
6. Reconnect all connectors to the computer unit.

Location
The computer unit is located in the top of the module as shown below. In the Dual Cabinet
Controller the computer unit is located in the Control Module.
xx0500001858
Description
A Operator’spanel
B Capacitor
C Computer unit © Copyright 2004-2008 ABB. All rights reserved.
D Panel unit
E Axis computer
Required equipment
Equipment Note
Computer unit DSQC 639
325.
toolkit.

Continued
Equipment Note
Removal
The procedure below details how to remove the computer unit.
NOTE!
The computer unit can have different design. The procedure how to remove the computer
unit is the same.
1.
DANGER!
2.
esd
WARNING!
information in section WARNING - The unit is
3. Disconnect all connectors from the computer NOTE! Make a note of any connections.
unit.
4. Remove the transportation screw.
xx0600003048
• A: transportation screw

Continued
5. Support the computer unit beneath by hand
and push the spring lock in the arrow
direction.
WARNING!
Prevent the computer unit from falling down xx0600002965
due to gravity when releasing the spring lock • A: Spring lock

by supporting the computer unit from
beneath by hand.
6. Let the front end of the computer unit down
and pull the unit out.
xx0600002966
Refitting
The procedure below details how to refit the computer unit.
NOTE!
The computer unit can have different design. The procedure how to refit the computer unit
is the same.
1. © Copyright 2004-2008 ABB. All rights reserved.
DANGER!
page 28.
2.
esd
WARNING!
safety information in section WARNING -
The unit is sensitive to ESD! on page 29

Continued
3. Fit the computer unit in position
xx0600002967
4. Push the computer unit up until the spring

lock snaps into position.
xx0600002968
5. Refit the transportation screw.

6. Reconnect all connectors to the computer
unit.

4.11. Replacement of motherboard in computer unit DSQC623
Location
The computer motherboard is located as shown in the figure below.
xx0400000870
A Solid state and hard disk drive

B Computer fans
C Power supply
D Computer motherboard
E Slot for Robot Communication Card (RCC)
F1-F4 Slots for PCI cards
Required equipment
Equipment Spare part no. Note

Computer A, SSD 3HAC020929-001 DSQC 600
Includes the memory
modules.
Computer B, HDD 3HAC020929-002 DSQC 600
Includes the memory
modules.
may be required. See references to the tools
references to these required.
Circuit Diagram See Circuit Diagram on page
341

Continued
Removal
The procedure below details how to remove the motherboard and related components.
1.
DANGER!
2.
esd
WARNING!
3. Remove the Computer Module. Detailed in section Replacement of
4. Remove the two attachment screws, and
open the Computer Module by pulling the
cover in the arrow direction.
XX0400000873
• A: attachment screw (2 pcs)

5. Remove the hard disk, flash disk drive bay. Detailed in section Replacement of hard
disk or IDE Flash module and cable in
6. Remove any PCI cards fitted to the moth- Detailed in section Replacement of PCI
erboard. cards in the computer unit DSQC623 on
page 245.

Continued
7. Disconnect all connectors from the
computer unit.
xx0300000340
Connectors:
• A: mouse cableNot used!
• B: keyboard cableNot used!
• C: USB 1
• D: USB 3
• E: VGANot used
• G: serial port ANot used
• H: LAN
• I: USB 2Not used
• J: USB 0Not used
8. Disconnect the connectors from the moth-
erboard.
xx0300000341
Connectors:
• F: power
• H: system fan
• I: front panel

Continued
9. Disconnect the connectors from the moth-
erboard.
A B
xx0300000342
Connectors:
• B: primary IDE
10. Remove the eight motherboard attachment NOTE! Always grip the board around the
screws. edges to avoid damage to the board or its
components!
11. Gently lift the motherboard out. NOTE! Immediately put the board in an
ESD safe bag or similar!
Refitting
The procedure below details how to refit the motherboard and related components.
1.
DANGER!

2.
esd
WARNING!
3. Gently lift the motherboard out of the ESD safe bag and NOTE! Always grip the
fit it into position in the computer module. board around the edges to
avoid damage to the board
or its components!
4. Secure the board with its eight attachment screws.
5. Reconnect all connectors to the motherboard. As specified in the illustra-
tions in section Removal.

Continued
6. Refit any PCI boards to the motherboard. Detailed in section
Replacement of PCI cards in
the computer unit DSQC623
on page 245.
7. Refit the hard disk, flash disk drive bay. Detailed in section
Replacement of hard disk or
IDE Flash module and cable
in computer unit DSQC623
on page 268.
8. Close the computer unit, and refit the attacment screws.
9. Refit the computer unit. Detailed in section
Replacement of computer
unit DSQC623 on page 222.

Location
The motherboard is located as shown in the figure below.
xx0600002912
A Motherboard
Required equipment
Equipment Note
Computer unit DSQC 639
325.
toolkit.

Continued
Removal (old design of computer unit DSQC 639)

The procedure below details how to remove the motherboard in the computer unit.
1.
DANGER!
2.
esd
WARNING!
ESD! on page 29
4. Remove the five attachment screws, and
remove the cover plate.
WARNING!
Be careful with the fan cable when opening
and removing the cover plate. The fan cable
must not be stretched.
xx0600002913

• B: fan cable
5. Disconnect the fan cable from the mother-
board.
6. Remove the Compact flash disk. Detailed in section Replacement of
Compact Flash memory in computer
7. Remove the PCI boards. Detailed in section Replacement of PCI
boards in the computer unit DSQC639
on page 249.

Continued
8. Remove the ten motherboard attachment
screws
xx0600002914

Always grip the board around the edges
to avoid damage to the board or its
components!
9. Gently lift the motherboard out. Immediately put the board in an ESD
safe bag or similar.
Removal (new design of computer unit DSQC 639)

The procedure below details how to remove the motherboard in the computer unit.
1.
DANGER!
2.
esd
WARNING!
ESD! on page 29
4. Remove the cover plate.
board.
6. Remove the fan. Detailed in section Replacement of fan
in computer unit DSQC639 on page 262
7. Remove the Compact flash disk. Detailed in section Replacement of

Continued
8. Remove the PCI boards. Detailed in section Replacement of PCI
on page 249.
9. Remove the nine motherboard attachment
screws B
Loosen the motherboard from the snap-lock
xx0800000205

• B: snap-lock
Always grip the board around the edges

to avoid damage to the board or its
components!
10. Gently lift the motherboard out. Immediately put the board in an ESD
safe bag or similar.
Refitting
The procedure below details how to refit the motherboard in the computer unit.
1.
DANGER! © Copyright 2004-2008 ABB. All rights reserved.

2.
esd
WARNING!
ESD! on page 29
3. Gently lift the motherboard out of the ESD Always grip the board around the edges
safe bag and fit it into position in the computer to avoid damage to the board or its
unit. components!

Continued
4. Secure the motherboard with its attachment
screws.
5. Refit the PCI boards. Detailed in section Replacement of PCI
on page 249.
6. Refit the flash disk. Detailed in section Replacement of
7. Reconnect the fan connector on the
motherboard and refit the coverplate.
8. Refit the computer unit. Detailed in sectionReplacement of

4.13. Replacement of DDR SDRAM memory on motherboard in computer unit DSQC639
4.13. Replacement of DDR SDRAM memory on motherboard in computer unit

DSQC639
Location
The DDR SDRAM memory is located as shown in figure below.
xx0600003031
A DDR SDRAM memory
Required equipment
Equipment Note
Computer unit DSQC639 DSQC 639
page 325.
DDR SDRAM 256MB See Computer unit DSQC 639 parts on
page 325.

Continued
Equipment Note
Standard toolkit
Removal (old design of the computer unit DSQC 639)

The procedure below details how to remove the DDR SDRAM memory on the motherboard
in the computer unit.
1.
DANGER!
2.
esd
WARNING!
3. Remove the computer unit Detailed in section Replacement of
4. Remove the five attachment srews, and
remove the cover plate.
WARNING!
must not be streched.
xx0600002913
• A: attachment screws (5 pcs)

• B: fan cable

Continued
board.
6. Gently lift the DDR SDRAM memory straight
up.
xx0600003033
• A: DDR SDRAM memory

NOTE! Always grip the memory around
the edges to avoid damage to the
memory or its components!
NOTE! Immedialety put the memory in
an ESD safe bag or similar!
Removal (new design of the computer unit DSQC 639)

The procedure below details how to remove the DDR SDRAM memory on the motherboard
in the computer unit.
1.
DANGER!

2.
esd
WARNING!
3. Remove the computer unit Detailed in section Replacement of
4. Remove the cover plate.

Continued
5. Gently lift the DDR SDRAM memory straight
up.
xx0600003033

NOTE! Immedialety put the memory in
an ESD safe bag or similar!
Refitting
The procedure below details how to refit the DDR SDRAM memory on the motherboard in
the computer unit DSQC639.
1.
DANGER!
2.
esd
WARNING!
ESD! on page 29

Continued
3. Gently lift the DDR SDRAM memory out of
the ESD safe bag and fit it into position on the
motherboard.
xx0600003033

4. Reconnect the fan connector on the
motherboard and refit the coverplate.
5. Refit the computer unit. Section Replacement of computer unit
DSQC639 on page 226.

4.14. Replacement of PCI cards in the computer unit DSQC623
Location
A number of PCI cards may be fitted in the slots in the Computer Module as shown in the
figure below:
• Interbus Master/Slave with copper interface
• Interbus Master/Slave with fiber-optic interface
• Robot communication card
• Ethernet card
• DeviceNet master/slave
• Profibus DP master/slave
• Dual RS-232 card
xx0400000870
A Solid state drive / hard disk drive

B Computer unit fan
C Power Supply
D Main computer motherboard
Required equipment
Equipment Art no. Note

Interbus master/slave, copper wire 3HAC11819-1 DSQC 529
Interbus communication is
also described in “Applica-
tion manual - Interbus”.

Continued
Equipment Art no. Note

Interbus master/slave, optical fibre 3HAC12092-1 DSQC 512
Interbus communication is
also described in “Applica-
tion manual - Interbus”.
Robot Com. Card 3HAC12816-1 DSQC 602
Always to be fitted in slot 1
as shown in the figure in
section Location.
Only used in CM.
Ethernet card 3HAC15639-1 DSQC 612
Only used in multirobot
control applications!
DeviceNet master/slave 3HAC12817-1 DSQC 603
DeviceNet communication
is also described in "Appli-
cation manual - DeviceNet”
Profibus DP master/slave 3HAC023047-001 DSQC 637
Profibus communication is
also described in "Applica-
tion manual - Profibus"
Dual RS-232 card 3HAC14864-1 DSQC 614
Always to be fitted in slot 5
as shown in the figure in
section Location.
Other tools and procedures may be These procedures include
required. See references to these references to the tools
procedures in the step-by-step required.
instructions below.
Application manual - Profibus 3HAC023008-001 Contains information on
how to configure the system
for Profibus cards.
Application manual - Interbus 3HAC023009-001 Contains information on © Copyright 2004-2008 ABB. All rights reserved.
for Interbus cards.
Application manual - DeviceNet 3HAC020676-001 Contains information on
for DeviceNet cards.
Circuit Diagram 3HAC024480-004 Complete control system

Continued
Removal
The procedure below details how to remove the cards.
1.
DANGER!
2.
esd
WARNING!
3. Remove the computer unit. Detailed in section
4. Open the Computer Module. Detailed in section
Replacement of
motherboard in computer
5. Identify the card to be replaced. The barcode sticker contains
information on type designa-
tion.
6. Disconnect any cables to/from the card. Make a note of which cables
are disconnected.
7. Remove the Torx attachment screw on top of the card NOTE! Always grip the card
bracket. around the edges to avoid
damage to the card or its
components!
8. Gently lift the card straight up. NOTE! Immediately put the
card in an ESD safe bag or
similar!
Refitting
The procedure below details how to refit the cards.
1.
DANGER!

Continued
2.
esd
WARNING!
3. Fit the card in position by pushing the card into the socket NOTE! Always grip the card
on the motherboard. around the edges to avoid
Secure it with its attachment screw. damage to the card or its
components!
4. Connect any additional cables to the card. Reconnect as noted on dis-
assembly.
5. Close the computer unit. Detailed in section
Replacement of
6. Refit the computer unit. Detailed in section
7. Make sure the robot system is configured to reflect the Detailed in documents
communication units installed. specified in section Required
equipment.

4.15. Replacement of PCI boards in the computer unit DSQC639
Location
A number of boards may be fitted in the slots in the computer unit as shown in the figure
below:
• Ethernet card
• Interbus Master/Slave with copper interface
• Interbus Master/Slave with fiber-optic interface
• Profibus-DP Master/Slave
• DeviceNet Master/Slave single
• DeviceNet Master/Slave dual
• PROFINET Master/Slave
xx0600002915
Description
A Slot for PCI cards
Continued
Required equipment

Ethernet card 3HAC15639-1 DSQC 612 Only used in
multirobot applications.
Interbus Master/Slave copper 3HAC11819-1 DSQC 529 Interbus communi-
wire cation is described in "Applica-
tion manual - Interbus"
Interbus Master/Slave optical 3HAC5579-1 DSQC 512 Interbus communi-
fibre cation is described in "Applica-
tion manual - Interbus"
Profibus-DP Master/Slave 3HAC023047-001 DSQC 637 Profibus communi-
cation is described in "Applica-
tion manual - Profibus"
DeviceNet Master/Slave single 3HAC025779-001 DSQC 658 Devicenet commu-
nication is described in "Appli-
catiopn manual - DeviceNet"
DeviceNet Master/Slave dual 3HAC025780-001 DSQC 659 DeviceNet commu-
nication is described in "Appli-
cation manual - DeviceNet"
PROFINET Master/Slave 3HAC030327-001 DSQC 678 PROFINET com-
munication is described in
"Application manual -
PROFINET master/slave"
Standard toolkit The contents are described in
section Standard toolkit, IRC5
on page 317.
be required. See references to references to tools required.
Application manual - Profibus 3HAC023008-001 Contains information on how to
configure the system for
Profibus cards.

Application manual - Interbus 3HAC023009-001 Contains information on how to
Interbus cards.
Application manual - DeviceNet 3HAC020676-001 Contains information on how to
DeviceNet cards.
Application manual -PROFINET 3HAC031975-001 Contains information on how to
master/slave configure the system for
PROFINET master/slave card
DSQC 678.
341.

Continued
Removal
The procedure below details how to remove the PCI cards from the computer unit.
1.
DANGER!
page 28.
2.
esd
WARNING!
29
3. Remove the computer unit. Detailed in section Replacement
of computer unit DSQC639 on
page 226.
4. Open the computer unit. Detailed in section Replacement
of motherboard in computer unit
5. Identify the card to be replaced. The barcode sticker contains
information on type designation.
6. Disconnect any cables to/from the card Make a note of which cables are
disconnected.
7. Remove the attachment screw on top of the card
bracket.
xx0600002916
NOTE! Always grip the card
around the edges to avoid
damage to the card or its
components!
8. Gently lift the card straight up. NOTE! Immediately put the card
in an ESD safe bag or similar!

Continued
Refitting
The procedure below details how to refit the PCI cards in the computer unit.
1.
DANGER!
page 28.
2.
esd
WARNING!
29
3. Fit the card in position by pushing the card into the NOTE! Always grip the card
socket on the motherboard. Secure it with its around the edges to avoid
attachment screw on top of the card bracket. damage to the card or its
components!
4. Reconnect any additional cables to the card.
5. Close the computer unit. Detailed in section Replacement
6. Refit the computer unit. Detailed in section Replacement
page 226.
7. Make sure the robot system is configured to reflect Detailed in section Required
the PCI cards installed. equipment on page 250.

4.16. Replacement of fieldbus adapter in the computer unit DSQC639
Location
The following fieldbus adapter may be fitted in the compact flash slot as shown in the figure
below:
• EtherNet/IP Fieldbus Adapter
• PROFIBUS Fieldbus Adapter
• PROFINET Fieldbus Adapter
xx0700000162
A Compact flash slot for fieldbus adapters
Required equipment

EtherNet/IP Fieldbus Adapter 3HAC027652-001 DSQC 669, Ethernet/IP communi-
cation is described in "Application
manual - EtherNet/IP Fieldbus
adapter"

Continued

PROFIBUS Fieldbus Adapter 3HAC026840-001 DSQC 667, PROFIBUS communi-
manual - PROFIBUS Fieldbus
Adapter"
PROFINET Fieldbus Adapter 3HAC031670-001 DSQC 688, PROFINET communi-
manual - PROFINET Fieldbus
Adapter"
Application manual - EtherNet/IP 3HAC028509-001 Contains information on how to
Fieldbus adapter configure the system for Ethernet/
IP Fieldbus Adapter DSQC 669.
Application manual - PROFIBUS 3HAC029338-001 Contains information on how to
Fieldbus Adapter configure the system for
PROFIBUS Fieldbus Adapter
DSQC 667.
Application manual - PROFINET 3HAC031974-001 Contains information on how to
Fieldbus Adapter configure the system for
PROFINET Fieldbus Adapter
DSQC 688.
Standard toolkit The contents are described in
section Standard toolkit, IRC5 on
page 317.
Removal
The following procedure details how to remove the fieldbus adapter from the computer unit.
1.
DANGER!
observe the safety information in section © Copyright 2004-2008 ABB. All rights reserved.
2.
esd
WARNING!
4. Open the computer unit. Detailed in section Replacement of
motherboard in computer unit DSQC639
on page 235

Continued
5. Identify the fieldbus adapter. The barcode sticker contains information
on type designation.
6. Disconnect the cable to/from the fieldbus
adapter.
7. Loosen the attachment screws (2 psc) on
front of the fieldbus adapter to release the
fastening mechanism.
NOTE!
Only loosen the attachment screws. Do not
remove them.
xx0700000193
• A: Attachment screws (2 pcs)

• B: Fastening mechanism

Continued
8. Grip the loosen attachment screws and
gently pull the fieldbus adapter out in the
arrow direction.
xx0700000195
Refitting
The following procedure details how to refit the fieldbus adapter in the computer unit.
1.
DANGER!
page 28.
2. © Copyright 2004-2008 ABB. All rights reserved.
esd
WARNING!
safety information in section WARNING -
The unit is sensitive to ESD! on page 29

Continued
3. Fit the fieldbus adapter in position by NOTE! Always grip the fieldbus adapter
pushing the fieldbus adapter along the around the edges to avoid damage to the
rails on the motherboard. adapter or its components.
WARNING!
Push carefully so no pins are damaged.
Make sure that the adapter is pushed
straight onto the rails.
xx0700000194
4. Secure it with its attachment screws (2

pcs) on front of the fieldbus adapter.
xx0700000201
• A: Attachment screws
• B: Fastening mechanism
5. Reconnect the cable to the fieldbus
adapter.
6. Close the computer unit. Detailed in section Replacement of
motherboard in computer unit DSQC639 on
page 235
7. Refit the computer unit. Detailed in section Replacement of

Continued
8. Make sure the robot system is configured
to reflect the fieldbus adapter installed.

4.17. Replacement of fan in computer unit DSQC623
Location
The computer fan is located in the back of the computer unit as shown below.
xx0400000870
A Solid state drive / hard disk drive

B Computer unit fan
C Power Supply
Required equipment
Equipment Note
Computer unit fan See Computer unit DSQC 623 parts on page
324.
toolkit!

Continued
Removal
The procedure below details how to remove the computer unit fan.
1.
DANGER!
page 28.
2.
esd
WARNING!
29
page 222.
5. Disconnect the connectors. Detailed in section Replacement
6. Remove the attachment screws.
xx04000000875
• A: Attachment screw (4
pcs/fan)

4 R e p a ir a c t iv it ie s , c o n t ro lle r IR C 5
Continued
Refitting
The procedure below details how to refit the computer unit fan.
1.
DANGER!
2.
esd
WARNING!
4. Reconnect the connectors. Detailed in section
Replacement of
5. Close the computer unit, and refit the attachment screws.
6. Refit the computer unit. Detailed in sectionReplace-
ment of computer unit

Location
The computer fan is located as shown in the figure below.
xx0600002917
A Fan

Required equipment
Equipment Note
Fan See Computer unit DSQC 639 parts on page
325.
toolkit.

Continued
Removal (old design of the computer unit DSQC 639)

The procedure below details how to remove the fan in the computer unit.
1.
DANGER!
2.
esd
WARNING!
ESD! on page 29
WARNING!
must not be stretched.
board.
6. Remove the attachment screw.
xx0600002919

• B: fan cable

Continued
7. Remove the fan from the cover plate in arrow
direction.
xx0600002920
Removal (new design of the computer unit DSQC 639)

The procedure below details how to remove the fan in the computer unit.
1.
DANGER!
2.
esd
WARNING!

ESD! on page 29
board.

Continued
6. Straighten the fan plate locking device to
loosen the fan unit.
Remove the fan unit.
A
xx0800000206
• A: fan plate locking device

7. Press out the plastic rivets.
Remove the fan from the fan plate.
A
xx0800000207
• A: plastic rivet (4 pcs)

Refitting (old design of the computer unit DSQC 639)

The procedure below details how to refit the fan in the computer unit.
1.
DANGER!
page 28.

Continued
2.
esd
WARNING!
29
3. Refit the fan on the cover plate.
4. Refit the attachments screw.
5. Reconnect the cable to the motherboard.
6. Close the computer unit. Detailed in section Replacement
page 226.
Refitting (new design of the computer unit DSQC 639)

The procedure below details how to refit the fan in the computer unit.
1.
DANGER!
2.
esd
WARNING!
ESD! on page 29

Continued
3. Refit the fan on the fan plate.
Press in the plastic rivets to fasten the fan on
the fan plate.
A
xx0800000207
• A: plastic rivet (4 pcs)

4. Refit the fan unit in to the computer unit.
Fold the fan plate locking device to fasten the
fan unit to the computer unit.
A
xx0800000206
• A: fan plate locking device

5. Reconnect the cable to the motherboard.
6. Close the computer unit. Detailed in section Replacement of

7. Refit the computer unit. Detailed in section Replacement of

4.19. Replacement of hard disk or IDE Flash module and cable in computer unit DSQC623
4.19. Replacement of hard disk or IDE Flash module and cable in computer unit
DSQC623
Location
Either the hard disk drive or the solid state drive and cable are located in a bay in the computer
module as shown in the figure below.
xx0400000870
A Bay for hard disk and IDE Flash module

B Cage attachment screws, hard disk and solid state drive cages
C Switches and LEDs
Required equipment

HDD mass memory with 3HAC020988-001 Includes all required mounting
carrier hardware.
To be used with Computer Module
only.
Includes ABB VxWorks boot image
software to correctly reboot the
robot controller.
IDE Flash Module 256MB 3HAC020988-008 Includes all required mounting
with carrier hardware.
To be used with Computer Module
only.
Includes ABB VxWorks boot image
software to correctly reboot the
robot controller.
Standard toolkit!
may be required. See references to the tools required.
references to these

Continued
Removal
The procedure below details how to remove the hard disk drive or the solid state drive and
cable.
1.
DANGER!
2.
esd
WARNING!
ESD! on page 29
5. Unscrew the cage attachment screws for the
drive cages, and pull the cage out in arrow
direction.
xx0400000879
• A: Cage attachment screw (2

pcs)
6. Disconnect the ribbon cable from the unit.
xx0400000941
• A: Hard disk, solid state drive

• B: Flat ribbon cable connection,
40 pin

Continued
7. Disconnect the 40 pin interface cable from the
motherboard.
xx0400000895
• A: Primary IDE connector

8. Remove and replace the complete cage and
drive assembly.
Refitting
The procedure below details how to refit the hard disk drive or the solid state drive and cable.
1.
DANGER!
2.
esd
WARNING! © Copyright 2004-2008 ABB. All rights reserved.

ESD! on page 29
3. Fit the complete cage and drive assembly and
secure it with its attachment screws.
4. Reconnect the flat ribbon cable to the unit.
xx0300000407
• A: Hard disk, IDE Flash

• B: Flat ribbon cable
connection, 40 pin

Continued
5. Reconnect the flat ribbon cable to the primary
xx0400000895
• A: Primary IDE connector

6. The jumper delivered with the IDE
flash module from ABB
(3HAC020988-008), shall not be
Note
used.
Make sure the drive to be used is defined as
"Master".
7. Push the cage back in to the computer unit, and Shown in the figure in section
secure it with the attachment screws. Location.
8. Make sure no cable is damaged, and close the Detailed in section Replacement of
computer unit motherboard in computer unit

4.20. Replacement of Compact Flash memory in computer unit DSQC639
Location
The Compact Flash memory is located in the computer unit as shown in the figure below.
xx0600002922
A Slot for Compact Flash memory © Copyright 2004-2008 ABB. All rights reserved.
NOTE!
Only use Compact flash memory supplied by ABB.
Required equipment
Equipment Note
Compact Flash 256MB DSQC 656 256MB
NOTE! Only use Compact flash memory
supplied by ABB.
Includes ABB Vx-Works boot image
software to correctly reboot the robot
controller.
page 325.

Continued
Equipment Note
Compact Flash 2GB DSQC 656 2GB
NOTE! Only use Compact flash memory
supplied by ABB.
Includes ABB Vx-Works boot image
software to correctly reboot the robot
controller.
page 325.
Standard toolkit
See references to these procedures in the step-
Removal
The procedure below details how to remove the Compact Flash memory from the computer
unit.
1.
DANGER!
2.
esd
WARNING!

ESD! on page 29
3. Gently, pull the Compact Flash memory out in
arrow direction.
xx0600002923

Continued
Refitting
The procedure below details how to refit the Compact Flash memory in the computer unit.
1.
DANGER!
2.
esd
WARNING!
ESD! on page 29
3. Refit the Compact Flash memory.
xx0600002924 © Copyright 2004-2008 ABB. All rights reserved.

4.21. Replacement of computer power supply in computer unit DSQC623
Location
The computer power supply is located in the computer unit as shown below.
xx0400000870
A Solid State drive / hard disk drive

B Computer unit fan
C Power supply
Required equipment
Equipment Note
Computer power supply DSQC 625

324.
toolkit!

Continued
Removal
The procedure below details how to remove the computer power supply.
1.
DANGER!
page 28.
2.
esd
WARNING!
29
page 222.
5. Loosen the attachment screw and remove the air
deflector plate. A
B
xx0400001135
• B: air deflector plate
6. Disconnect the 24V and 0V power cables.
7. Disconnect the connector connected to the mother
board.
8. Disconnect the power cables to the computer fan
units.

Continued
A
xx0400000909
• A: attachment screw (4
pcs)
10. Remove the computer power supply.
Refitting
The procedure below details how to refit the computer power supply.
1.
DANGER!
page 28.
2.
esd
WARNING!

unit please observe the safety information in section
29
3. Refit the computer power supply.
4. Refit the Attachment screws.
A
xx0400000909

Continued
6. Refit the air deflector plate, and tighten the
attachment screw. A
B
xx0400001135
• B: air deflector plate
7. Refit the computer unit cover. Detailed in section Replacement
page 222.

4.22. Replacement of servo drive units, rectifierand capacitorunit
Location
The illustration below shows the location of the servo drive units, rectifiers and capacitor
units in a Single Cabinet Controller.
In the Dual Cabinet Controller the servo drive components are located in the Drive Module.
xx0500001858
B Capacitor
C Computer unit
D Panel board unit

E Axis computer
F Drive system ( drive units and rectifier)
Configuration
The drive module exists in a number of versions, these are described in section Configuration
of the drive system, IRC5 on page 88
Required equipment
Equipment Note
Drive units, rectifiers and capacitor units Specified in section Configuration of the
drive system, IRC5 on page 88
Standard toolkit!

Continued
Equipment Note
Removal
The procedure below details how to remove the servo drive units, rectifiers and capacitor
units.
1.
DANGER!
page 28.
2. If an EPS board (option Electronic See Replacement of EPS board DSQC 646
Position Switches) is mounted the Axis on page 285.
computer unit needs to be removed
before removal of the servo drive units,
rectifiers and capacitors.
3. Disconnect all connectors from the unit
to be replaced.
4. Remove the busbar between units.
xx0400000998
Parts:
• A: bus bar

Continued
5. Remove the drive unit after unscrewing
its attachment screws .
xx0500002001
Parts:
• A: drive unit
Refitting
The procedure below details how to refit the servo drive units, rectifiers and capacitor units.
1.
DANGER!
2. Fit the unit in its intended position and orientation.
Secure it with its attachment screws.
3. Reconnect all busbars between units.
4. Reconnect any connectors disconnected at removal.
5. Refit the Axis computer unit if EPS board is mounted See Replacement of EPS
(option Electronic Position Switches). board DSQC 646 on page
285.

4.23. Replacement of Axis computer
Location
The illustration below shows the location of the axis computer in the Single Cabinet
Controller.
In the Dual Cabinet Controller the axis computer is located in the Drive Module.
xx0500001858
B Capacitor
C Computer unit
D Panel board unit © Copyright 2004-2008 ABB. All rights reserved.
E Axis computer
F Drive system ( drive units and rectifier)
Removal
The procedure below details how to remove the axis computer.
1.
DANGER!

Continued
2.
esd
WARNING!
on page 29
3. Disconnect all connectors from the axis NOTE!
computer. Make a note of any connections,
A
B B
xx0500002002
5. Remove the axis computer.
Refitting
The procedure below details how to refit the axis computer.
1.
DANGER!

Continued
2. Fit the new axis computer.
A
B B
xx0500002002
4. Reconnect all the connectors.

4.24. Replacement of EPS board DSQC 646
General
An EPS board is mounted in the Single Cabinet Controller or Drive Module if the option
Electronic Position Switches is used.
Location
The EPS board is mounted behind the axis computer.
xx0600003203
A EPS board
B Axis computer
Removal
1.
DANGER!
2.
esd
WARNING!

Continued
3. Disconnect the following cables connected
to the EPS board and axis computer:
• Plug contact in I/O connector
• Power cables
• SMB cables
• Ethernet cables
xx0700000101
A: Plug contact in I/O connector

B: Power cables
C: SMB cables
D: Ethernet cables
computer and remove the axis computer. A
B B
xx0500002002

Continued
5. Remove the attachment screws of the EPS
board and remove the EPS board.
A
B B
xx0600003204
• A: EPS board
Refitting
1.
DANGER!
2.
esd
WARNING!
the EPS board. A
xx0700000087

Continued
4. Connect the short SMB cable and both
Ethernet cables to the EPS board before
mounting the board. These connections
may be difficult to reach once the board is
mounted.
The two Ethernet connectors on the EPS
board are interchangeable (it does not
matter which is connected to the main
computer and which is connected to the axis
computer).
xx0600003303
5. Refit the EPS board and the axis computer

(see Removal on page 285).
6. Refit all the cables (see Removal on page
285).

4.25. Replacement of SafeMove board DSQC 647
General
A SafeMove board is mounted in the Single Cabinet Controller or Drive Module if the option
SafeMove is used.
NOTE!
After replacement of the safety controller, the SafeMove configuration must be downloaded
to the new safety controller and then validated. For more information, see Application manual
- SafeMove
Location
The SafeMove board is mounted behind the axis computer.
xx0800000102
A SafeMove board
B Axis computer

Continued
Removal
The procedure below details how to remove the SafeMove board.
1.
DANGER!
2.
WARNING!
information in section The unit is sensitive
to ESD! on page 27.
3. Disconnect the cables connected to the
SafeMove board and the cables between
the SafeMove board and the axis
computer:
computer and remove the axis computer. A
B B
xx0500002002

Continued
5. Remove the attachment screws of the
SafeMove board and remove the A
SafeMove board.
B
B
xx0800000104
• A: SafeMove board
Refitting
The procedure below details how to refit the SafeMove board.
1.
DANGER!

2.
WARNING!
information in section The unit is sensitive
to ESD! on page 27.

Continued
the SafeMove board.
xx0800000204
• A: EMC strips
4. Connect both SMB cables and both
Ethernet cables to the SafeMove board
before mounting the board. These
connections may be difficult to reach once
the board is mounted.
The two Ethernet connectors on the
SafeMove board are interchangeable (it
does not matter which is connected to the
main computer and which is connected to
the axis computer).
xx0800000103
• A: SMB1 cable
• B: SMB2 cable
• C: Ethernet cables
5. Refit the SafeMove board and the axis
computer, see Removal on page 290.
6. Refit all cables, see Removal on page 290.

Continued
7. After replacement of the safety controller,
the SafeMove configuration must be
downloaded to the new safety controller
and then validated. For more information,
see Application manual - SafeMove

4.26. Replacement of Remote Service box
General
A Remote Service box is mounted in the Single Cabinet Controller or in the Control Module
of the Dual Cabinet Controller if option Remote Service is used.
Location
The illustration below shows the Remote Service box in the Single Cabinet Controller.
For Dual Cabinet Controller the Remote Service box is located on the botton in the Control
Module.

xx0800000094
A Remote Service box
Required equipment
Equipment Note
Remote Service box DSQC 680
See Controller system parts on page 321.
toolkit.
See references to these procedures in the

Continued
Removal
The following procedure details how to remove the Remote Service box.
1.
DANGER!
2.
WARNING!
in section The unit is sensitive to ESD! on page
27.
3. Disconnect all connectors from the Remote
Service box.
4. Push the spring locks in the arrow direction
and lift the box out.
xx0800000091
• A: Spring lock
Refitting
The following procedure details how to refit the Remote Service box.
1.
DANGER!

Continued
2.
WARNING!
in section The unit is sensitive to ESD! on page
27.
3. Fit the Remote Service box in position.
xx0800000092
4. Push the Remote Service box in the arrow

direction until the spring locks snaps into
position.
xx0800000093
5. Reconnect all connectors to the Remote

Service box.

4.27. Replacement of Contactor Interface Board
Location
The contactor interface board is located on the left wall in the Single Cabinet Controller.
In the Dual Cabinet Controller the contactor interface board is located on the left wall in the
Drive Module.
A
C
D
xx0400001058
A MOTOR ON contactor K42

B MOTOR ON contactor K43
C Brake contactor
D Jumpers (3pcs)
Required equipment
Equipment Note
Contactor Interface board DSQC 611
See Controller system parts on page
321.

Standard toolkit!
Other tools and procedures may be required. See These procedures include references
references to these procedures in the step-by-step to the tools required.
instructions below.
Circuit Board See Circuit Diagram on page 341.

Continued
Removal
The procedure below details how to remove the contactor board.
1.
DANGER!
2.
esd
WARNING!
3. Disconnect all connectors. NOTE!
Make a note of any connections.
B
xx0400001062
• A: contactor interface board

5. Remove the contactor interface board.
6. If SafeMove option is used, the plugs in the
limit switch override contact (X23) pin 1 and
4, must be moved to the new contactor
interface board.
Use a small flat pliers to remove the plugs.
xx0800000035
• A: plug (2 pcs)

Continued
Refitting
The procedure below details how to refit the contactor board.
1.
DANGER!
2.
esd
WARNING!
3. If SafeMove is used, mount the plugs in the The limit switch override contact must be
limit switch override contact (X23) pin 1 and plugged and not used when using
4. SafeMove.
A
xx0800000035
• A: plug (2 pcs)
4. Refit the contactor interface board.
B
xx0400001062
• A: contactor interface board


4.28. Replacement of drive system fans
Location
The illustration below shows the drive system fans in the Single Cabinet Controller.
In the Dual Cabinet Controller the drive system fans are located in the back of the Drive
Module.
A
B
xx0500002011
A Fan (4 pcs)
B Cover
C Attachment screw (4 pcs)
Required equipment
Equipment Note © Copyright 2004-2008 ABB. All rights reserved.

Fan with receptacle See Miscellaneous parts on page 326.
toolkit.
required. see references to these tools required.
below.

Continued
Removal
The following procedures details how to remove the drive system fan.
Action Note /illustration

1.
DANGER!
2. Remove the moist dust filter magazine. How to remove the moist dust filter
(Option) magazine is detailed in section
Replacement of moist dust filter on page
173.
3. Loosen the four attachment screws to the
cover.
4. Remove the cover.
5. Disconnect the connector to the fan.
6. Push the fan upwards and remove it.
xx0500002015
• A: fan
• B: attachments
• C: grooves
Refitting
The following procedures details how to refit the drive system fan.
1.
DANGER!

Continued
2. Reconnect the connector to the fan.
3. Refit the fan by placing the attachments in
the back of the fan housing in the grooves.
xx0500002015
• A: fan
• B: attachments
• C: grooves
4. Refit the cover and the attachment
screws.
5. Refit the moist dust filter magazine. How to refit the moist dust filter magazine
(Option) is detailed in section Replacement of moist
dust filter on page 173.

4.29. Replacement of transformer unit
Location
The illustration below shows the location of the transformer unit in the Single Cabinet
Controller.
In the Dual Cabinet Controller the transformer is located in the back of the Drive Module.
xx0500002028
A Transformer
Required equipment
Equipment Note
Transformer unit 13kVA, 6kVA, 1,8kVA
See Miscellaneous parts on page 326.
toolkit

Continued
Removal
The following procedures details how to remove the transformer unit.
1.
DANGER!
2.
WARNING!
The transformer weighs between 15 and 40 kg,
use a hoist and lifting slings.
(Option) magazine is detailed in section
Replacement of moist dust filter on
page 173.
4. Loosen the attachment screws.
xx0500002027 © Copyright 2004-2008 ABB. All rights reserved.

• A: attachment screw (4pcs)
• B: cover
5. Remove the cover.
6. Disconnect the two grounding wires (gnye,
blue).
7. Disconnect the mains power supply wires, NOTE!
Make a note of the terminal to which
each of the wires are connected. This
will facilitate reconnection to the same
terminal.

Continued
8. Remove the two transformer attachment
screws.
xx0500002032
• A: attachment screw (2pcs)

9. Push the transformer unit side ways and lift it
out with lifting slings and a hoist.
xx0500002033
Refitting
The following procedure details how to refit the transformer unit.
1.
DANGER!
2.
WARNING!
The transformer weighs between 15 and 40
kg, use a hoist and lifting slings.
3. Fit the new transformer in place with a hoist
and lifting slings.
5. Reconnect the mains power supply wires and
grounding wires.

Continued
6. Refit the cover.
7. Refit the moist dust filter magazine. (Option) How to refit the moist dust filter
magazine is detailed in section
page 173.

4.30. Replacement of brake resistor bleeder
Location
The illustration below shows the location of the brake resistor bleeder (behind the cover) in
the Single Cabinet Controller.
In the Dual Cabinet Controller the brake resistor bleeder is located in the Drive Module.
xx0500002022
A Brake resistor bleeder (behind plate, not visible).
Required equipment
Equipment Note
Brake resistor bleeder See Miscellaneous parts on page 326.
Standard toolkit

Continued
Removal, Single Cabinet Controller

The following procedure details how remove the brake resistor bleeder in the Single Cabinet
Controller.
1.
DANGER!
page 28.
(Option) magazine is detailed in section Replacement
of moist dust filter on page 173.
3. Remove the covers in the back of the
controller.
xx0700000418
• A: top cover
• B: transformer cover

Continued
4. Disconnect the two connectors from the
bleeder.
xx0500002020

• B: connectors
• C: brake resistor bleeder
• D: bleeder attachment screw (4 pcs)
5. Loosen the attachment screws for the
brake resistor bleeder.
6. Llift the bleeder slightly and push it in to
release the attachments.
7. Lift the bleeder straight up.
Removal, Dual Cabinet Controller

The following procedure details how to remove the brake resistor bleeder in the Dual Cabinet
Controller, Drive Module.
1.
DANGER!
2. Remove the moist dust filter magazine. (Option) How to remove the moist dust filter
page 173.
3. Remove the covers in the back of the Control
Module and Drive Module.
4. Remove cable protectors on the Drive Module
gables. Leave the lower screws in place.
5. Loosen the screws that fastens the Control 6 pcs M8 screws
Module to the Drive Module.

Continued
6. Lift carefully the Control Module in the front edge
and pull the Control Module 10 cm so it rests on
the upper front edge of the Drive Module.
7. Disconnect the two connectors from the bleeder.
8. Loosen the attachment screws for the bleeder.
9. Lift the bleeder slightly and push it in to release
the attachments.
10. Lift the bleeder straight up.
Refitting, Single Cabinet Controller

The following procedure details how to refit the brake resistor bleeder in the Single Cabinet
Controller..
1.
DANGER!
page 28.
2. Slide the new bleeder in to place and fit
the attachent screws in the key hole
attachments.
xx0500002020

• B: connectors
• C: brake resistor bleeder
• D: bleeder attachment screw (4
pcs)
3. Tightening the four attachment screws.
4. Reconnect the connectors.
5. Refit the covers.

Continued
6. Refit the moist dust filter magazine. How to refit the moist dust filter magazine
(Option) is detailed in section Replacement of moist
dust filter on page 173.
Refitting, Dual Cabinet Controller

The following procedure details how to refit the brake resitor bleeder in to the Dual Cabinet
Controller, Drive Module.
1.
DANGER!
page 28.
2. Slide the new bleeder in to place and fit the
attachent screws in the key hole attachments.
3. Tightening the four attachment screws..
4. Reconnect the connectors.
5. Lift carefully the Control Module in the front edge
and push the Control Module 10 cm to it’s mounting
position on top of the Drive Module.
6. Refit the screws that fastens the Control Module to 6 pcs M8 screws
the Drive Module.
7. Refit the cable protectors on the Drive Module
gables.
8. Refit the covers.
9. Refit the moist dust filter magazine. (Option) How to refit the moist dust filter
Replacement of moist dust filter
on page 173.


5 Reference information, IRC5
5.1. Introduction

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

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

5.3. Screw joints
5.3. 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.
Tightening torque (Nm)

Dimension
Class 4.8, oil-lubricated
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0

5.4. Weight specifications
5.4. 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!

5.5. Standard toolkit, IRC5
5.5. 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, standard toolkit, IRC5
Tool Remark
Screw driver, Torx Tx10
Ball tipped screw driver, Torx Tx25
Screw driver, flat blade 4 mm
Screw driver Phillips-1
Box spanner 8 mm

5.6. 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 Document ID

Product Specification - Controller IRC5 with FlexPendant 3HAC021785-001
Operating manuals
The operating manuals contains instructions for daily operation of robot systems. The
operating manuals listed below is the English version.
Document name Document ID Note

IRC5 with FlexPendant 3HAC16590-1
Getting started 3HAC027097-001
RobotStudio 3HAC032104-001
Trouble shooting - IRC5 3HAC020738-001
Product manual, robot

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

Product manual, IRB 140 3HAC023297-001 © Copyright 2004-2008 ABB. All rights reserved.
Product manual, IRB 140 Type C 3HAC027400-001

Product manual, IRB 1400 3HAC021111-001
Product manual, IRB 1600 Type A 3HAC026660-001
Product manual, IRB 4400/4450S 3HAC022032-001
Product manual, IRB 6400RF 3HAC027076-001
Product manual, IRB 6600/6650 type A 3HAC020938-001
Product manual, IRB 6600/6650 type B 3HAC023082-001
Product manual, IRB 6650S 3HAC020993-001

Continued


5.7. Lifting equipment and lifting instructions
5.7. 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.

6 Spare Parts
6.1.1. Single Cabinet Controller
6 Spare Parts
6.1 Controller parts
General
The illustrations in this section show the locations of the parts in the IRC5 Single Cabinet
Controller.
The spare parts for the Single and Dual Cabinet Controller are in general identical but the
location of parts in the Dual Cabinet Controller are divided between the Control Module and
the Drive Module.
Controller system parts

The illustration below shows the placement of the controller system parts in the
recommended spare part list.
xx0600002680
Spare part no. Description Note

L 3HAC025338-001 Main Servo Drive Unit, D6 3B 3A DSQC 617

6 Spare Parts
Continued

L 3HAC025338-002 Main Servo Drive Unit, D6 2E 2C 2B DSQC 617
L 3HAC025338-003 Main Servo Drive Unit, D4 3E 1C DSQC 617
L 3HAC025338-004 Main Servo Drive Unit, D6 3T 3G DSQC 617
L 3HAC025338-006 Main Servo Drive Unit, D6 3W 3V DSQC 617
L 3HAC14550-1 Single servo drive unit DSQC 619
H 3HAC14549-1 Rectifier DSQC 618
H 3HAC14549-2 Rectifier DSQC 618
G 3HAC14551-1 Capacitor Unit, C2 DSQC 620
G 3HAC14551-3 Capacitor Unit, C4 DSQC 620
J 3HAC024488-001 Panel board unit DSQC 643
K 3HAC12815-1 Axis computer DSQC 601
E 3HAC12928-1 Control power supply DSQC 604
N 3HAC026254-001 Power distribution board DSQC 662
C 3HAC026289-001 Drive system power supply standard. DSQC 626A
C 3HAC020466-001 Drive system power supply ext. DSQC 627
P 3HAC026253-001 System power supply DSQC 661
D 3HAC12934-1 Customer I/O Power supply DSQC 608
M 3HAC14178-1 Customer I/O power supply DSQC 609
F 3HAC026585-001 Backup energy bank with adapter plate DSQC 655
F 3HAC025562-001 Backup energy bank DSQC 655
3HAC030439-001 Remote Service box DSQC 680
3HAC13389-2 Contactor interface board DSQC 611

6 Spare Parts
Continued
I/O System parts

The illustration below shows the placement of the I/O system parts in the recommended spare
part list.
xx0600002681

A 3HAC025784-001 ADCombi I/O DSQC 651
A 3HAC025917-001 Digital I/O DSQC 652
A 3HAC025918-001 Digital I/O with relay outputs DSQC 653
A 3HNE00554-1 Analog ±10V I/O DSQC 355A

6 Spare Parts
Continued
Computer unit DSQC 623 parts

The illustration below shows the placement of the computer unit parts in the recommended
spare part list.
xx0600002682

A 3HAC020929-006 Computer AC plus
A 3HAC020929-007 Computer BD plus
3HNE00025-1 Circuit board RIO
B 3HAC14944-1 RS-232/422 converter
C 3HAC12816-1 Robot com. card DSQC 602
D 3HAC15639-1 Ethernet card DSQC 612
D 3HAC023047-001 Profibus-DP adapter DSQC 637
D 3HNE00009-1 Profibus DP Slave unit
D 3HAC11819-1 Interbus slave with Cu DSQC 529
D 3HNE00006-1 Interbus-S Unit
D 3HAC5579-1 InterBus-S adap. DSQC 512 © Copyright 2004-2008 ABB. All rights reserved.
D 3HAC12817-1 DeviceNet M/S DSQC 603
E 3HAC021629-001 LED board with cover DSQC 631
3HAC020988-006 Fan right inside computer
3HAC020988-007 Fan left inside computer
3HAC020464-001 Computer power supply DSQC 625,
inside computer

6 Spare Parts
Continued
Computer unit DSQC 639 parts

The illustration below shows the placement of the computer unit parts in the recommended
spare part list.
C
xx0600003029

6 Spare Parts
Continued

A 3HAC025527-001 Computer unit DSQC 639
B 3HAC025465-001 Compact flash 256MB DSQC 656 256MB
B 3HAC025465-003 Compact flash 2GB DSQC 656 2GB
C 3HAC14944-1 RS-232/422 Converter DSQC 615
E, D, F 3HAC025779-001 DeviceNet Master/Slave Single DSQC 658
E, D, F 3HAC025780-001 DeviceNet Master/Slave Dual DSQC 659
E, D, F 3HAC15639-1 Ethernet card DSQC 612
E, D, F 3HAC11819-1 Interbus Master/Slave copper wire DSQC 529
E, D, F 3HAC5579-1 Interbus Master/Slave optical fibre DSQC 512
E, D, F 3HAC023047-001 Profibus-DP Master/Slave DSQC 637
E, D, F 3HAC030327-001 PROFINET Master/Slave DSQC 678
G 3HAC031670-001 PROFINET Fieldbus Adapter DSQC 688
I 3HAC16751-3 Fan
K 3HAC025097-016 DDR SDRAM 256MB
Miscellaneous parts
The illustration below shows the placement of the Miscellaneous parts in the recommended
spare part list.
xx0600002683
Spare part no Description Note

C 3HAC024138-001 Transfomer unit 13kVA

6 Spare Parts
Continued
Spare part no Description Note

C 3HAC024174-001 Transfomer unit 2,5kVA drive
C 3HAC024180-001 Transfomer unit 6kVA
A 3HAC024729-001 Heat exchange unit 45°C
A 3HAC024439-001 Heat exchange unit 52°C
D 3HAC024628-001 Brake resistor bleeder asm
B 3HAC021700-001 Fan with receptacle 52°C
B 3HAC021702-001 Fan with receptacle 45°C
G 3HAC021702-001 Fan with receptacle
3HAC021606-001 Cam Switch
3HAC12929-1 GTPU with 10m cable
E 3HAC027697-001 Moist dust filter Option
F 3HAC027641-001 Moist dust filter Option

6 Spare Parts
6.2.1. Manipulator variants
6.2 Manipulator cables
General
When ordering cables, consider the option numbers for the manipulators.
Manipulator Variants Option no.

IRB 140 Standard 435-2
Standard 6-0.8 435-87
High speed 435-44
High speed 6-0.8 435-87
IRB 1400 435-3
IRB 1410 435-70
IRB 1600 5-1.2 435-60
5-1.45 435-61
6-1.2 435-91
6-1.45 435-92
7-1.2 435-56
7-1.45 435-57
8-1.2 435-89
8-1.45 435-90
IRB 1600ID 4-1.5 435-79
IRB 2400 10kg 435-7
16kg 435-8
L 435-9
IRB 260 435-58
IRB 340 Standard 435-33
Wash down 435-34
Stainless wash down 435-35
2kg standard 435-47

2kg wash down 435-48
2kg stainless wash down 435-49
IRB 360 1 435-80
3 435-81
1 800 435-82
IRB 4400 45kg 435-37
60kg 435-38
L-10 435-41
L-30 435-42
IRB 6400RF 200-2.5 435-15
200-2.8 435-23
IRB 660 180-3.15 435-58
250-3.15 435-59
IRB 6600 175-2.55 435-16
225-2.55 435-17
175-2.8 435-22

6 Spare Parts
Continued
Manipulator Variants Option no.

IRB 6650 200-2.75 435-19
125-3.2 435-30
IRB 6650S 125-3.5 435-50
200-3.0 435-51
IRB 6620 150-2.2 435-64
IRB 6640 180-2.55 435-71
235-2.55 435-72
205-2.75 435-73
185-2.8 435-74
130-3.2 435-75
IRB 6640ID 200-2.55 435-76
170-2.75 435-77
IRB 6660 130-3.1 435-78
IRB 7600 500-2.3 435-6
400-2.55 435-18
340-2.5 435-24
150-3.5 435-36

6 Spare Parts
6.2.2. Manipulator cables
Signal cables, IRB 1400,IRB 1600
Art. no. Description Option no.

3HAC2493-1 Control cable signal L=7m 210-2
Signal cables, IRB 2400, IRB 260, IRB 4400, IRB 6400RF, IRB 660, IRB 6600, IRB 6650 and IRB 7600

Power cables, IRB 140

3HAC7996-1 Control cable power L=3m 210-1
Power cables, IRB 1400,IRB 1600, IRB 2400

3HAC2492-1 Control cable power L=7m Standard: 210-2 and 287-4
3HAC9038-1 Control cable power L=7m Foundry: 210-2 and 287-3
Wash: 210-2 and 287-5
Wash: 210-3 and 287-5
Wash: 210-4 and 287-5
Wash: 210-5 and 287-5

6 Spare Parts
Continued

Wash: 210-5 and 287-5
Wash: 210-5 and 287-5
Wash: 210-5 and 287-5
Wash: 210-5 and 287-5

3HAC8158-1 Control Cable power L=7m (435-33 or 435-34 or 435-35 or
435-47 or 435-48 or 435-49)
and 210-2
435-47 or 435-48 or 435-49)
and 210-3
435-47 or 435-48 or 435-49)
and 210-4
435-47 or 435-48 or 435-49)
and 210-5

3HAC029903-001 Control cable, power and signal (435-803 or 435-81 or 435-82)
L=3m

L=7m
L=15m
L=22m
L=30m

Clean room: 210-2 and 287-1

6 Spare Parts
Continued

Wash: 210-2 and 287-5
Wash: 210-3 and 287-5
Wash: 210-4 and 287-5
Wash: 210-5 and 287-5
Power cables, IRB 6400RF

3HAC8184-1 Control cable power L=7m 210-2 and 287-3
Power cable, IRB 6600, IRB 7600, IRB 660, IRB 6620, IRB 6640

3HAC026787-001 Control cable power L=7m (435-6 or 435-18 or 435-24 or
435-36) and 210-2
435-36) and 210-3
435-36) and 210-4
3HAC026787-004 Control cable power L=30m (435-6 or 435-18 or 435-24 or © Copyright 2004-2008 ABB. All rights reserved.
435-36) and 210-5

6 Spare Parts
6.2.3. Position switch cables
6.2.3. Position switch cables
IRB 1400
Axis 1

3HAC3363-1 Pos. switch cable L=7m 273-1
IRB 1600, 2400, 260, 4400, 6400RF and 340

Axis 1

IRB6600, 7600, 660 and 6620

Axis 1

3HAC13175-1 Pos. Switch 1 L=7m 273-1
3HAC13175-2 Pos. Switch 1 L=15m 273-2
3HAC13175-3 Pos. Switch 1 L=22m 273-3
3HAC13175-4 Pos. Switch 1 L=30m 273-4
Axis 2 and 3

3HAC13176-1 Pos. Switch 2/3 L=7m 274-1
3HAC13176-2 Pos. Switch 2/3 L=15m 274-2
3HAC13176-3 Pos. Switch 2/3 L=22m 274-3
3HAC13176-4 Pos. Switch 2/3 L=30m 274-4

6 Spare Parts
6.2.4. Fan cables
6.2.4. Fan cables
IRB6600 and 7600

3HAC022723-001 Harness - Axis 1&2 cooling (87-1 or 88-1 or 89-1) and
210-2
210-3
210-4
210-5
3HAC022708-001 Harness - axis 1/2/3 cooling (87-1 or 88-1 or 89-1) and
274-1 or 274-2 or 274-3 or
274-4

6 Spare Parts
6.2.5. CP/CS Harness IRB 6400RF
6.2.5. CP/CS Harness IRB 6400RF
CP/CS Canbus

3HAC9288-1 Harness CP/CS, CAN L=7m 16-1 and 90-2

6 Spare Parts
6.2.6. CP/CS Harness IRB 6600, 7600, 660, 6620 and 6640
6.2.6. CP/CS Harness IRB 6600, 7600, 660, 6620 and 6640
CP/CS

3HAC022957-001 Harness CP/CS L=7m 16-1 and 94-1
CP/CS Interbus

3HAC023024-001 Harness CP/CS, IBS L=7m 16-1 and 91-2
CP/CS/Profibus

3HAC022988-001 Harness CP/CS, PROFIB L=7m 16-1 and 92-2
CP/CS DeviceNet

3HAC022978-001 Harness CP/CS, DeviceNet L=7m 16-1 and 90-2


6 Spare Parts
6.2.7. Customer signal, CS/CP and CS
6.2.7. Customer signal, CS/CP and CS
IRB 1400

3HAC3346-1 Customer cable sign. L=7m 16-1 and 17-5 and 94-1
IRB 1600, 2400

3HAC3353-1 Customer cable sign. L=7m Standard: 94-1 and 287-4
3HAC8183-1 Customer cable sign. L=7m Foundry: 94-1 and 287-3
Wash: 94-1 and 287-5
Wash: 94-2 and 287-5
Wash: 94-3 and 287-5
Wash: 94-4 and 287-5
IRB 260

3HAC8183-1 Customer cable signal, L=7m Foundry: 94-1 and 287-3
Wash: 94-1 and 287-5

Wash: 94-2 and 287-5
Wash: 94-3 and 287-5
Wash: 94-4 and 287-5
IRB 340, 360

3HAC14860-1 Customer cable sign. L=7m 218-9 and 94-1

6 Spare Parts
6.2.8. Customer power-signal
6.2.8. Customer power-signal
IRB 1600, 260, 2400 and 4400

3HAC8183-1 Customer pow.-sign. L=7m 94-1 and 16-1 and 17-5 and
(287-3 or 243-5)
(287-3 or 243-5)
(287-3 or 243-5)
(287-3 or 243-5)
(287-4 or 243-1)
3HAC3354-1 Customer power-sign. L=15m 94-2 and 16-1 and 17-5 and
(287-4 or 243-1)
(287-4 or 243-1)
(287-4 or 243-1)
IRB 340

3HAC3358-4 Internal Customer cable L=3m 218-5 and 94-6

IRB 360

Euromap cables

3HAC024328-001 Cable EMP67, L=10m 671-2 and 673-1

6 Spare Parts
6.2.9. External axis cables
Power cable (stationary gun)

3HEA800736-001 Power cable (floor) L=7m 809-1
Power cable (robot gun)

Serial measurement cable

3HXD1411-70 Serial measurement cable 787-1
Miscellaneous cables

3HEA800964-003 SMB 2axis, standard IP65 785-3 or 785-6
3HXD1249-70 7:th axis floor cable 785-6

3HXD1249-70 7:th axis floor cable 785-3 or 785-2
3HXD1250-70 Resolver cable floor 785-2 or 785-5
3HXD1250-70 Resolver cable floor 785-6
3HXD1249-15 Motor cable, 7:th axis 785-3
3HXD1250-15 Resolver cable (Foundry) 785-3

6 Spare Parts

7 Circuit Diagram
7.1. Introduction
7 Circuit Diagram
7.1. Introduction
Definitions
This chapter specifies the circuit diagram of the IRC5 Controller.

7 Circuit Diagram
7.1. Introduction

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.
Except as may be expressly stated anywhere in this document, 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 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. © Copyright 2003 ABB
This document and parts thereof must not be reproduced or copied without ABB's written permission,
and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.
Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB at its then current charge.
© Copyright 2004 ABB ALL right reserved.
ABB Automation Technologies AB

Robotics
Sweden
Latest revision: Lab/Office: Status: Plant: = CAB

CONTROL SYS. IRC5 M2004 DESIGN 06 2008-07-17
Location: + CONTROLLER
Approved Sublocation: +
COPYRIGHT page Document no. Rev. Ind Page 1
Next 2
Prepared by, date: Approved by, date: Title page/cover sheet 3HAC024480-004 03 Total 153
Customer :
Control cabinet : CONTROL SYS. IRC5 M2004 DESIGN 06
Drawing number : CONTROL MODULE
Drawing version :
Manufacture :
Type :
Type of installation :
Control cabinet :
Mains voltage :
Supply :
Control voltage :
Year of construction :
Project start :
Project manager :
Last revision :
Designed by : sejesun
Designed date : 2008-07-17
Number of pages :
:

Location: + CONTROLLER
TITLE PAGE Document no. Rev. Ind Page 2
Next 3
1 2 3 4 5 6 7 8
Document no changed to 3HAC024480-004 Rev 00 used to be 3HAC020538-002 Rev 06

Added DESIGN 06 to page header
Changes made from old document 3HAC020538-002 Rev 06
Page 25 Deleted outlet flex, -X25 and -XP20. Changed cablenr -XT16 acc. to conn. tables Page <39 New pages with computer unit DSQC 639
Added interruptionspoints at -Q2 and -XT16. Moved outlet dual/single to 64.1 Page <39 New page with anybus main computer
Moved cable def 308, 309, 152, 153, 181, 182 to page 27
Page 39 Added objects from page 40.
Page 26 Deleted cablenr. 182 ( double insert ). Added :5, :6 to -G2-X2 Page 40 Moved -D31 and -D32 to page 39. Deleted page
Page 27 Deleted text 703, 704. Added cable def. 703, 704, 152, 153, 181, 182 Page 42 Changed second LED to IDE LED (YELLOW)
Page 27.1, 28.1 New pages with DSQC 609 Page 39-43 Added text DSQC623
Page 28 Changed output plug -G6-X1 to -G6-X2. Deleted cablenr 308 and 309 ( double insert ) Page 44 Moved -A9, -A7 to page 43. Deleted page
Added cable def. 703, 704 Page 45 Changed -X2, -X3 to -DP-S-X2 and -DP-M-X3
Page 29 Added black-box to show x-ref to page 38. Changed -E3 to int. fan, cable part -X11 Page 46 Changed -A38 to -A37
and text RCC to Main Computer Page 47 Added connection for dual devnet
Page 30 Added black-box to show x-ref to page 38 Page 51, 52, 53, 54 Changed components on I/O-cards. Added DSQC-number
Page 31 Added black-box to show x-ref to page 38 Page 55 Deleted text. Added DSQC-number
Page 32 Added interruptionspionts at -X7 Page 56 Deleted page ( old I/O-card )
Page 33 Changed -S21.1.X11 to -S21.1.X1 Page 59 Changed plugsymbol on -X21 (socket-pin) and -X20 (pin-socket)
Page 34 Added cablenr. and interruptionpoints. Added conn. 21-22 on -S21.3 EM.PB Renumbered page 25-61 to page 32-72
Changed adapter and changed -S21.1.X12 to -S21.1.X1 Renumbered page REV to page 3
Page 34.1, 35.1, 37 Deleted (flexcontrol ) Renumbered page 20 to page 31
Page 34.2 New page with hot-plug option Renumbered page 21 to page 30
Page 35 Added cablenr. and interruptionpoints. Shifted connection 1 and 5 on both -X9. Renumbered page 22-24 to page 20-22
Changed adapter and changed -S21.1.X13 to -S21.1.X1
Page 35.2 New page with hot-plug option

Page 36 Deleted cable nr 205-213 ( double insert ). Changed text and parts ETH_FPU
Page 36.1 Changed connections on button -S22. Added interruptionpoints + conn. ETH_FPU
Page 38 Show x-ref to page 29, 30, 31. Added symbolic line to -X1 and -X2
Latest revision: Lab/Office: Status: 2008-07-17 Plant: = CAB

CONTROL SYS. IRC5 M2004 DESIGN 06 Location: + REV
REVISION INFORMATION Approved
Sublocation: +
Document no. Rev. Ind Page 3
Next 3.1
Prepared by, date: Approved by, date: 3HAC024480-004 03 Total 153
1 2 3 4 5 6 7 8
Changes made from old document 3HAC020538-002 Rev 06
Page 63 Added Q1 Option : Flange Disconnect Page 82 Added symbolic line to -R1.MP1-3 and -R1.MP4-6
Page 64 Added Z2 to transformer T1.3 + interruption points for outgoing power Page 83 Added jumpers to -R1.MP1-3:10-12 16-18, interruptionpoints at -XS/XP1 and 2,
Page 64.1 New page for Option : sevice outlet symbolic line at MP1-3 and MP4-6. Changed -R1.SMB to -R2.SMB.
Page 65 Deleted -XS25. Added interruptionpoints. Changed symbol -G1-X2, -X3 Page 87 Added symbolic line to -R1.MP1-3 and -R1.MP4-6
Page 66 Changed cablenr out from -XT16 according to connection tables Page 88 Added jumpers to -R1.MP1-3:10-12 16-18, interruptionpoints at -XS/XP1 and 2,
Page 66.1 New page with DSQC 662 symbolic line at MP1-3 and MP4-6. Changed -R1.SMB to -R2.SMB with numbers.
Changed -R1.MP to -R1.H1, -R1-MP1-3, -R1-MP4-6 with numbers.
Page 67 Deleted cablenr 463 - 470 (double insert).
Added int. points at -X1, -X5, -X10, -X11, -X21. Added internal fan -E4 Page 93 Added interruptionpoints at -XS/XP1 and 2
Page 68 Changed connections -X9:2 and :3. Redrawed connection -K44:3 Page 97, 104, 111, 118 Changed plug DT-tag to -XP/XT8 and -XS/XP8
Page 69 Added interruptionpoints at -X2. Changed text to main computer. Page 100 Added jumpers to -R1.MP:C1-B3 C2-B4, interruptionpoints at -XS/XP1 and 2.
Added conn. to EPS Deleted -R1.SMB:G and H, added keypin M
Page 70 Added interruptionpoints at -X4, text at -X8, ref. to EPS Page 101 and 102 Deleted connection CPM on =MAN-R1.CP/CS : B3
Page 70.1 Added new page with EPS Page 107 Added interruptionpoints at -XS/XP1 and 2. Deleted -R1.SMB:G and H, added keypin M
Page 74 Changed text to drive unit no 8 Page 114 Added interruptionpoints at -XS/XP1 and 2. Deleted -R1.SMB:G and H, added keypin M
Page 76 Changed cable -6007 to -4007 Page 121 Changed terminal -Y1 to dual press -DP. Added interruptionpoints at -XS/XP1 and 2
Page 77 Added text IRB260 to 9 axis Page 126 Added interruptionpoints at -R1FAN.SW23
Renumbered page 62-77 to page 82-99 Page 126.1 New page with cooling axes single cab.
Renumbered page 78-80 to page 23-26 Page 127, 128, 133, 134, 135 Added earth between -XS/XP13 and =MAN-R1.CP/CS
Page 129 Changed DevNet shield -XS/XP13 to socket. Changed IBS to -A38-X5, PBUS to -A33
Page 136-140 Added R to robot model IRB6400
Page 138 Added interruptionpoints at -XS/XP1 and 2
Page 140 Changed -R1.CP/CS. Added text and cable def.
Renumbered page 81-85 to page 110-114

Sublocation: +
Document no. Rev. Ind Page 3.1
Next 3.2
1 2 3 4 5 6 7 8
Document 3HAC024480-004 Rev 01
Page 52 A38.1 Renamed ETHERNET/IP was before named ANYBUS.

Option with connecton to cabinet wall not exist.
Page 52 New A38.2 PROFIBUS
Page 181 Option Interbus connection A37, was A38.
Page 34-37 Added connection to XT31

Page 50 Added connections for option Remote service and Safe move.
Page 51 Added connection for remote service.
Page 73 New, option Remote service added.
Page 90 Added connection to Safe move.
Page 92.1 New, option Safe move added.

Page 92.2 New, option Safe move added.
Page 94 Taco signal removed from fan.
Page 98 Adapter cable A43.X5 added.
Page 120 IRB360 added.
Page 171 Alternative number making added for cable XP/XS1 - MAN R1.MP.
Page 172 Alternative number making added for cable XP/XS1 - MAN R1.MP.
Page 23 A33.1 PrpfiNet added.

Page 52 New Fieldbus adapter A38.3 ProfiNet IO.
Page 57.1 New sheet for ProfiNet.

Sublocation: +
Next 4
Table of contents ABB_table_of_contents
Plant Location Page Page description Page supplementary field Date Editor
CAB CONTROLLER 1 COPYRIGHT page Approved 2008-04-01 sejesun
CAB CONTROLLER 2 TITLE PAGE Approved 2008-04-01 sejesun
CAB REV 3 REVISION INFORMATION Approved 2008-04-01 sejesun
CAB REV 3.1 REVISION INFORMATION Approved 2008-04-01 sejesun
CAB REV 3.2 REVISION INFORMATION Approved 2008-07-17 sejesun
CAB CM 4 Table of contents: (1 - 33) Approved 2008-07-17 sejesun
CAB CM 10 Device: =CAB+CM-1 - =CAB.DC+CM-G5 Approved 2008-07-16 sejesun
CAB CM 11 Device: =CAB.DC+CM-G6 - =CAB+DM-Z2 Approved 2008-07-16 sejesun
CAB CM 13 Plugs : =CAB+CM-A36-A1 - =CAB+EXT-SLO.5-A21-S21.1.X1 Approved 2008-07-16 sejesun
CAB CM 14 Plugs : =MAN+R1-1400-SMB - =CAB.DC+CM-G4-X2 Approved 2008-07-16 sejesun
CAB CM 15 Plugs : =CAB.DC+CM-G4-X2 - =CAB+EXT-SLO.3-A21-X10 Approved 2008-07-16 sejesun

CAB CM 16 Plugs : =CAB+EXT-SLO.4-A21-X10 - =CAB.DC+CM-1600-XP/XT5.2 Approved 2008-07-16 sejesun
CAB CM 17 Plugs : =CAB.SC+CM-1600-XP/XT5.2 - =CAB+CM-XS/XP13 Approved 2008-07-16 sejesun
CAB CM 18 Plugs : =CAB+CM-XS/XP13 - =CAB.SC+CM-SLO.1-XT31 Approved 2008-07-16 sejesun
CAB.SC CM 20 FRONT VIEW OF SINGLE CABINET Approved 2008-04-01 sejesun
CAB.SC CM 21 SIDE VIEWS OF SINGLE CABINET Approved 2008-04-01 sejesun
CAB.DC CM 22 VIEW OF CONTROL MODULE DUAL CABINET Approved 2008-04-01 sejesun
CAB CM 23 VIEW OF COMPUTER UNIT AND PANEL BOARD Approved 2008-07-16 sejesun
CAB.DC DM 24 VIEW OF DRIVE MODULE DUAL CABINET Approved 2008-04-01 sejesun
CAB DM 25 VIEW OF CONTACTOR UNIT AND AXIS COMPUTER UNIT Approved 2008-04-01 sejesun
CAB DM 26 VIEW OF DRIVE UNIT VARIANTS Approved 2008-04-01 sejesun
CAB CM 30 CONTROL MODULE Approved 2008-04-01 sejesun
CAB CM 31 BLOCK DIAGRAM CM Approved 2008-04-01 sejesun
CAB.DC CM 32 MAINS CONNECTION DUAL CABINET Approved 2008-04-01 sejesun
CAB CM 33 PROCESS POWER SUPPLY Approved 2008-04-01 sejesun

Location: + CM
Table of contents: (1 - 33) Document no. Rev. Ind Page 4
Next 5
Prepared by, date: Approved by, date: Table of contents 3HAC024480-004 03 Total 153
CAB.DC CM 34 OPTION: POWER SUPPLY FOR DUAL CABINET Approved 2008-04-01 sejesun
CAB.DC CM 35 OPTION: POWER SUPPLY DSQC 609 FOR DUAL CABINET Approved 2008-04-01 sejesun
CAB.SC CM 36 OPTION: POWER SUPPLY FOR SINGLE CABINET Approved 2008-04-01 sejesun
CAB.SC CM 37 OPTION: POWER SUPPLY DSQC 609 FOR SINGLE CABINET Approved 2008-04-01 sejesun
CAB CM 38 EMERGENCY STOP Approved 2008-04-01 sejesun
CAB CM 39 RUN CHAIN OPERATING MODE SELECTOR, 3 MODES Approved 2008-04-01 sejesun
CAB CM 40 EMERGENCY STOP Approved 2008-04-01 sejesun
CAB CM 41 RUN CHAIN Approved 2008-04-01 sejesun
CAB CM 42 RUN CHAIN OPERATING MODE SELECTOR, 2 MODES Approved 2008-04-01 sejesun
CAB CM 43 RUN CHAIN EXT OPERATING MODE SELECTOR, 2 MODES Approved 2008-04-01 sejesun
CAB CM 44 RUN CHAIN EXT OPERATING MODE SELECTOR, 2 MODES OPTION : HOT PLUG Approved 2008-04-01 sejesun
CAB CM 45 RUN CHAIN EXT OPERATING MODE SELECTOR, 3 MODES Approved 2008-04-01 sejesun
CAB CM 46 RUN CHAIN EXT OPERATING MODE SELECTOR, 3 MODES OPTION : HOT PLUG Approved 2008-04-01 sejesun
CAB CM 47 FPU, FLEXPENDANT Approved 2008-04-01 sejesun
CAB CM 48 FPU, FLEXPENDANT OPTION: HOT PLUG Approved 2008-04-01 sejesun
CAB CM 49 OPTION: EXTERNAL CONNECTION SYSTEM SIGNALS Approved 2008-04-01 sejesun

CAB CM 50 MAIN COMPUTER DSQC 639 Approved 2008-04-01 sejesun
CAB CM 51 MAIN COMPUTER DSQC 639 Approved 2008-04-01 sejesun
CAB CM 52 FIELDBUS ADAPTER:ETHERNET/IP, PROFIBUS and PROFINET IO Approved 2008-07-17 sejesun
CAB CM 53 MAIN COMPUTER AC/BD Approved 2008-04-01 sejesun
CAB CM 56 MAIN COMPUTER AC/BD ROBOT COMM. CARD DSQC 602 Approved 2008-04-01 sejesun
CAB CM 57 PROFIBUS DP M/S Approved 2008-07-16 sejesun
CAB CM 57.1 PROFINET Approved 2008-07-17 sejesun
CAB CM 58 INTERBUS M/S Approved 2008-04-01 sejesun
CAB CM 59 DEVICENET SINGLE/DUAL ADAPTER Approved 2008-04-01 sejesun
CAB CM 60 DEVICENET ADAPTER Approved 2008-04-01 sejesun
CAB CM 61 DUAL RS232 CARD Approved 2008-04-01 sejesun
CAB CM 62 ETHERNET CARD Approved 2008-04-01 sejesun

Location: + CM
Next 6
CAB CM 63 DIGITAL PART OF COMBI I/O AND DIGITAL I/O UNIT Approved 2008-04-01 sejesun
CAB CM 64 DIGITAL I/O UNIT Approved 2008-04-01 sejesun
CAB CM 65 COMBI I/O UNIT Approved 2008-04-01 sejesun
CAB CM 66 RELAY I/O UNIT Approved 2008-04-01 sejesun
CAB CM 67 RELAY I/O UNIT Approved 2008-04-01 sejesun
CAB CM 68 ANALOGUE I/O UNIT Approved 2008-04-01 sejesun
CAB CM 69 REMOTE I/O UNIT Approved 2008-04-01 sejesun
CAB CM 70 INTERBUS SLAVE Approved 2008-04-01 sejesun
CAB CM 71 PROFIBUS DP SLAVE Approved 2008-04-01 sejesun
CAB CM 72 ENCODER UNIT Approved 2008-04-01 sejesun
CAB CM 73 REMOTE SERVICE Approved 2008-04-01 sejesun
CAB CM 80 DRIVE MODULE Approved 2008-04-01 sejesun
CAB DM 82 MAINS CONNECTION Approved 2008-04-01 sejesun
CAB DM 83 TRANSFORMER UNIT Approved 2008-04-01 sejesun
CAB DM 84 OPTION : SERVICE OUTLET Approved 2008-04-01 sejesun
CAB.DC DM 85 POWER SUPPLY DSQC 626 AND 627 FOR DUAL CABINET Approved 2008-04-01 sejesun
CAB.SC DM 86 POWER SUPPLY DSQC 626 AND 627 FOR SINGLE CABINET Approved 2008-04-01 sejesun
CAB.SC DM 87 POWER SUPPLY DSQC 661 AND 662 FOR SINGLE CABINET Approved 2008-04-01 sejesun
CAB DM 88 CONTACTOR BOARD Approved 2008-04-01 sejesun
CAB DM 89 POWER UNIT SERVO DISCONNECTOR Approved 2008-04-01 sejesun
CAB DM 90 AXIS COMPUTER UNIT Approved 2008-04-02 sejesun
CAB DM 91 AXIS COMPUTER UNIT Approved 2008-04-01 sejesun
CAB DM 92 EPS Approved 2008-04-01 sejesun
CAB DM 92.1 SAFE MOVE Approved 2008-04-01 sejesun
CAB DM 92.2 SAFE MOVE Approved 2008-04-01 sejesun
CAB DM 93 RECTIFIER AND BLEEDER Approved 2008-04-01 sejesun
CAB DM 94 FAN UNIT Approved 2008-04-01 sejesun
CAB DM 95 ADDITIONAL AXIS 1-3, DRIVE UNIT NO 7 Approved 2008-04-01 sejesun

Location: + CM
Next 7
CAB DM 98 EXTERNAL AXIS no 7 Approved 2008-04-01 sejesun
CAB DM 99 EXTERNAL AXIS no 8 - 9 Approved 2008-04-01 sejesun
CAB CM 110 IRB 140 CABINET MODULE Approved 2008-04-01 sejesun
CAB DM 111 SERVO DRIVE SYSTEM IRB 140 Approved 2008-04-01 sejesun
CAB DM 112 CONTROL CABLE IRB 140 Approved 2008-04-01 sejesun
CAB.DC CM 113 CUSTOMER SIGNAL DUAL CABINET IRB 140 Approved 2008-04-01 sejesun
CAB.SC CM 114 CUSTOMER SIGNAL SINGLE CABINET IRB 140 Approved 2008-04-01 sejesun
CAB CM 120 IRB 340 AND IRB360 CABINET MODULE Approved 2008-04-01 sejesun
CAB DM 121 SERVO DRIVE UNITS IRB 340 AND IRB360 Approved 2008-04-01 sejesun
CAB DM 122 CONTROL CABLE IRB 340 AND IRB360 Approved 2008-04-01 sejesun
CAB.DC CM 123 CUSTOMER SIGNAL DUAL CABINET IRB 340 AND IRB360 Approved 2008-04-01 sejesun
CAB.SC CM 124 CUSTOMER SIGNAL SINGLE CABINET IRB 340 AND IRB360 Approved 2008-04-01 sejesun
CAB.DC CM 133 CUSTOMER SIGNALS DUAL CABINET IRB 1400 Approved 2008-04-01 sejesun
CAB.SC CM 134 CUSTOMER SIGNALS SINGLE CABINET IRB 1400 Approved 2008-04-01 sejesun
CAB.DC CM 135 POSITION SWITCHES DUAL CABINET IRB 1400 Approved 2008-04-01 sejesun
CAB.SC CM 136 POSITION SWITCHES SINGLE CABINET IRB 1400 Approved 2008-04-01 sejesun
CAB DM 141 SERVO DRIVE UNIT IRB 1600 Approved 2008-04-01 sejesun
CAB.DC CM 143 CUSTOMER POWER/SIGNAL DUAL CABINET IRB 1600 Approved 2008-04-01 sejesun
CAB.SC CM 144 CUSTOMER POWER/SIGNAL SINGLE CABINET IRB 1600 Approved 2008-04-01 sejesun
CAB.DC CM 145 POSITION SWITCH DUAL CABINET IRB 1600 Approved 2008-04-01 sejesun
CAB.SC CM 146 POSITION SWITCH SINGLE CABINET IRB 1600 Approved 2008-04-01 sejesun
CAB CM 150 IRB 260 and IRB 2400 CABINET MODULE Approved 2008-04-01 sejesun
CAB DM 151 SERVO DRIVE UNIT IRB 2400 Approved 2008-04-01 sejesun

Location: + CM
Next 8
CAB CM 170 IRB 660 and IRB 66xx-76xx CABINET MODULE Approved 2008-04-01 sejesun
CAB DM 171 SERVO DRIVE SYSTEM IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB DM 172 CONTROL CABLE IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB.DC CM 173 POSITION SWITCH 1 DUAL CABINET IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB.SC CM 174 POSITION SWITCH 1 SINGLE CABINET IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB.DC CM 175 POSITION SWITCH 2/3 DUAL CABINET IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB.SC CM 176 POSITION SWITCH 2/3 SINGLE CABINET IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB.DC DM 177 POS.SWITCH 2/3 AND COOLING AXES 1/2 DUAL CABINET IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB.SC DM 178 COOLING AXES 1/2 SINGLE CABINET IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB.DC CM 179 CUSTOMER POWER/SIGNAL DUAL CABINET IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB.SC CM 180 CUSTOMER POWER/SIGNAL SINGLE CABINET IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB CM 181 DevNet//IBUS//PBUS ADDITION TO CP/CS IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB.DC CM 182 CUSTOMER POWER/SIGNAL DUAL CABINET PROFIBUS IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB.DC CM 183 CUSTOMER POWER/SIGNAL DUAL CABINET INTERBUS IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB.DC CM 184 CUSTOMER POWER/SIGNAL DUAL CABINET DEVICE NET IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB.SC CM 185 CUSTOMER POWER/SIGNAL SINGLE CABINET PROFI BUS IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB.SC CM 186 CUSTOMER POWER/SIGNAL SINGLE CABINET INTERBUS IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB.SC CM 187 CUSTOMER POWER/SIGNAL SINGLE CABINET DEVICE NET IRB 6600 - 7600 Approved 2008-04-01 sejesun
CAB CM 200 IRB 6400R CABINET MODULE Approved 2008-04-01 sejesun
CAB DM 201 SERVO DRIVE SYSTEM IRB 6400R Approved 2008-04-01 sejesun

Location: + CM
Next 9
CAB DM 202 CONTROL CABLE IRB 6400R Approved 2008-04-01 sejesun
CAB CM 203 POSITON SWITCH IRB 6400R Approved 2008-04-01 sejesun
CAB CM 204 CUSTOMER POWER/SIGNAL/BUS IRB 6400R Approved 2008-04-01 sejesun

Location: + CM
Next 10
Prepared by, date: Approved by, date: Table of contents 03 Total 153
Location name Location description Page Location name Location description Page
=CAB+CM- -1 52 =CAB+DM- -A41.1 MAIN SERVO DRIVE UNIT 141
=CAB+CM-A61 -1 73 =CAB+DM- -A41.1 MAIN SERVO DRIVE UNIT 151
=CAB+CM- -10086 73 =CAB+DM- -A41.1.3 SINGLE SERVO DRIVE UNIT 95
=CAB+CM- -A3 COMPUTER UNIT AC/BD 53 =CAB+DM- -A41.1.3 SINGLE SERVO DRIVE UNIT 98
=CAB+CM- -A21 PANEL BOARD 38 =CAB+DM- -A41.1.4 SINGLE SERVO DRIVE UNIT 96
=CAB+EXT- -A21 EXT.CONTROL PANEL 43 =CAB+DM- -A41.1.5 SINGLE SERVO DRIVE UNIT 99
=CAB+CM- -A21 PANEL BOARD 44 =CAB+DM- -A41.2 RECTIFIER 93
=CAB+EXT- -A21 EXT.CONTROL PANEL 44 =CAB+DM- -A41.3 CAPACITOR UNIT 93
=CAB+CM- -A21 PANEL BOARD 45 =CAB+DM- -A42 AXIS COMPUTER BOARD 90
=CAB+EXT- -A21 EXT.CONTROL PANEL 45 =CAB+DM- -A43 CONTACTOR UNIT 88
=CAB+CM- -A21 PANEL BOARD 46 =CAB+DM- -A44 OPTION : EPS 92
=CAB+EXT- -A21 EXT.CONTROL PANEL 46 =CAB+DM- -A44 OPTION: SAFE MOVE DSQC647 92.1
=CAB+CM- -A21 PANEL BOARD 49 =CAB+CM- -A61 OPTION: REMOTE SERVICE BOX 73
=CAB+EXT-A21 -A22 ADAPTER 43 =CAB+DM- -C1 CAPACITOR 172
=CAB+EXT-A21 -A22 ADAPTER 44 =CAB+CM-A3 -D32 SOLID STATE DRIVE 53
=CAB+EXT-A21 -A22 ADAPTER 45 =CAB+DM- -F1 AUTOMATIC FUSE 89

=CAB+EXT-A21 -A22 ADAPTER 46 =CAB.DC+DM- -F2 AUTOMATIC FUSE 85

=CAB+CM- -A23 OPTION:STATUSLED ON FRONT 39 =CAB.SC+DM- -F2 AUTOMATIC FUSE 86
=CAB+CM- -A31 MAIN COMPUTER DSQC639 50 =CAB.SC+DM- -F2 AUTOMATIC FUSE 87
=CAB+CM- -A32 ROBOT COMMUNICATION CARD 56 =CAB+DM- -F4 EARTH FAULT BREAKER 84
=CAB+CM- -A33 PROFIBUS DP M/S 57 =CAB+DM- -F5 CIRCUIT BREAKER 84
=CAB+CM- -A33.1 PROFINET DSQC678 57.1 =CAB+DM- -F6 OPTION:CIRCUIT BRAKER 82
=CAB+CM- -A34 DUAL RS232 CARD 61 =CAB+CM- -FPU1 FLEXPENDANT 47
=CAB+CM- -A35 DEVICE NET ADAPTER 59 =CAB+CM- -FPU1 FLEXPENDANT 48
=CAB+CM- -A36 ETHERNET CARD 62 =CAB.DC+DM- -G1 DRIVE POWER SUPPLY 85
=CAB+CM- -A37 INTERBUS M/S (OPTICAL FIBRE) 58 =CAB.SC+DM- -G1 DRIVE POWER SUPPLY 86
=CAB+CM- -A37 INTERBUS M/S (COPPER WIRE) 58 =CAB.SC+DM- -G1 POWER SUPPLY 87
=CAB+CM- -A38.1 ETHERNET/IP Fieldbus adapter DSQC 669 52 =CAB+CM- -G2 PROCESS POWER SUPPLY 33
=CAB+CM- -A38.2 PROFIBUS Fieldbus adapter DSQC 667 52 =CAB.SC+DM- -G2 POWER DISTRIBUTION BOARD 87
=CAB+CM- -A38.3 PROFINET Fieldbus adapter DSQC 688 52 =CAB+CM- -G3 ULTRA CAP 33
=CAB+CM- -A39 OPTION:232/422/485 SERIE CONVERTER 51 =CAB.SC+DM- -G3 ENERGY BANK 87
=CAB+CM-A3 -A39 OPTION:232/422/485 SERIE CONVERTER 55 =CAB.DC+CM- -G4 CUSTOMER POWER SUPPLY 34
=CAB+DM- -A41.1 MAIN SERVO DRIVE UNIT 90 =CAB.DC+CM- -G4 CUSTOMER POWER SUPPLY 35
=CAB+DM- -A41.1 MAIN SERVO DRIVE UNIT 111 =CAB.SC+CM- -G4 CUSTOMERPOWERSUPPLY 36

Location: + CM
Device: =CAB+CM-1 - =CAB.DC+CM-G5 Document no. Rev. Ind Page 10
Next 11
Prepared by, date: Approved by, date: Device list 3HAC024480-004 03 Total 153
Location name Location description Page Location name Location description Page
=CAB.DC+CM- -G6 DEVICENET POWER SUPPLY 35 =CAB+EXT- -S21.1 2-MODE SELECTOR 44
=CAB.SC+CM- -G6 DEVICENET POWERSUPPLY 36 =CAB+EXT-A21 -S21.1 3-MODE SELECTOR 45
=CAB.SC+CM- -G6 DEVICENET POWER SUPPLY 37 =CAB+EXT-A21 -S21.1 3-MODE SELECTOR 46
=CAB.DC+CM- -G7 CUSTOMER POWER SUPPLY 35 =CAB+CM- -S21.2 MOTOR ON PB 39
=CAB.DC+CM- -G8 CUSTOMER POWER SUPPLY 35 =CAB+CM- -S21.2 MOTOR ON PB 42
=CAB+CM- -G31 COMPUTER POWER SUPPLY 53 =CAB+EXT-A21 -S21.2 MOTOR ON PB 43
=CAB+CM-A3 -G31 COMPUTER POWER SUPPLY 54 =CAB+EXT-A21 -S21.2 MOTOR ON PB 44
=CAB+DM- -H1 STATUS DIOD DUAL CABINET 89 =CAB+EXT-A21 -S21.2 MOTOR ON PB 45
=CAB+CM- -I/Ox DIG. PART OF COMBI I/O AND DIG. I/O UNIT 63 =CAB+EXT-A21 -S21.2 MOTOR ON PB 46
=CAB+CM- -I/Ox DIGITAL I/O UNIT 64 =CAB+CM- -S21.3 EMERGENCY PB 38
=CAB+CM- -I/Ox COMBI I/O UNIT 65 =CAB+EXT-A21 -S21.3 EMERGENCY PB 43
=CAB+CM- -I/Ox DIG. PART OF RELAY I/O UNIT 66 =CAB+EXT-A21 -S21.3 EMERGENCY PB 44
=CAB+CM- -I/Ox ANALOGUE I/O UNIT 68 =CAB+EXT-A21 -S21.3 EMERGENCY PB 45
=CAB+CM- -I/Ox REMOTE I/O UNIT 69 =CAB+EXT-A21 -S21.3 EMERGENCY PB 46
=CAB+CM- -I/Ox INTERBUS SLAVE 70 =CAB+EXT-A21 -S22 OPTION : HOT PLUG 44
=CAB+CM- -I/Ox PROFIBUS DP SLAVE 71 =CAB+EXT-A21 -S22 OPTION : HOT PLUG 46
=CAB+CM- -I/Ox ENCODER UNIT 72 =CAB+CM- -S22 OPTION : HOT PLUG 48
=CAB+DM- -K42 MOTORS ON CONTACTOR 1 89 =CAB+DM- -T1 TRANSFORMER UNIT 83
=CAB+DM- -K43 MOTORS ON CONTACTOR 2 89 =CAB+DM- -T1 TRANSFORMER UNIT 83
=CAB+DM- -K44 BRAKE CONTACTOR 89 =CAB+CM-A38.2 -Z1 Profibus DSQC667 52
=CAB+CM-A33.1 -LAN1 PROFINET CONNECTIONS =CAB+CM-A33.1 -Z1 57

=CAB+CM-E3 -M1 INTERNAL FAN 38 =CAB+DM- -Z1 OPTION:MAINS LINE FILTER 82

=CAB+CM-E2 -M1 EXTERNAL COMPUTER FAN 39 =CAB+DM-Z2 -Z2 REAKTOR UNIT 83
=CAB+DM-E4 -M1 OPTION : INTERNAL FAN 88 =CAB+DM-Z2 -Z2 REAKTOR UNIT 83
=CAB+DM-E41 -M1 FAN UNIT 94
=CAB+DM-P1 -P1 OPTION :DUTY TIME COUNTER 88
=CAB+DM- -Q1 MAINS SWITCH 82
=CAB+DM- -Q1 OPTION :FLANGE DISCONNECT 82
=CAB.DC+CM- -Q2 MAIN SWITCH 32
=CAB+DM- -R1.1 BLEEDER 93
=CAB+CM- -R3 120 ohm 63
=CAB+CM- -R5 120 ohm 66
=CAB+CM- -R8 120 ohm 70
=CAB+CM- -R9 120 ohm 71
=CAB+CM- -R11 120 OHM 60
=CAB+CM- -S21.1 3-MODE SELECTOR 39
=CAB+CM- -S21.1 2-MODE SELECTOR 42
=CAB+EXT- -S21.1 2-MODE SELECTOR 43

Location: + CM
Device: =CAB.DC+CM-G6 - =CAB+DM-Z2 Document no. Rev. Ind Page 11
Next 13
Prepared by, date: Approved by, date: Device list 3HAC024480-004 03 Total 153
Plugs overview ABB Plug overview
Plug Plug
Location Unit Connection Function text Page Location Unit Connection Function text Page
+CM -A36 -A1 DRIVE MODULE 2 62 +EXT -A21 -DP3 DUAL PRESS 46
+CM -A36 -A2 DRIVE MUDULE 3 62 +EXT -A21 -DP4 DUAL PRESS 43
+CM -A36 -A3 DRIVE MODULE 4 62 +EXT -A21 -DP4 DUAL PRESS 44
+CM -A31 -A7 Yellow ETH_SERVICE 50 +EXT -A21 -DP4 DUAL PRESS 45
+CM -A32 -A7 Yellow ETH_SERVICE 56 +EXT -A21 -DP4 DUAL PRESS 46
+CM -A31 -A8 Green ETH_FPU 50 +DM -DP388 DUAL PRESS 88
+CM -A32 -A8 Green ETH_FPU 56 +DM -DP389 DUAL PRESS 88
+CM -A31 -A9 Red AXC1 ETH_DRIVE 50 +DM -DP734 DUAL PRESS 88
+CM -A32 -A9 Red ETH_DRIVE 56 +DM -DP735 DUAL PRESS 88
+DM -A42-X1 POWER SUPPLY EPS/ AXC 90 +CM -A33 -DP-M1 OPTION : PROFIBUS IRB 6600-7600 181
+DM -A43.XP5 PTC, 0V Brake 98 +DM -E1.XP2 FAN UNIT 94
+CM -A3 -C1 CHASSIS BLOWER 54 +DM -E1.XS2 FAN UNIT 94
+CM -A3 -C2 CHASSIS BLOWER 54 +CM -A37 -FO1 REMOTE IN 58
+CM -A35 -CHA-J1 DEVICENET ADAPTER 59 +CM -A37 -FO2 REMOTE OUT 58
+CM -A35 -CHB-J2 DUAL DEVICENET ADAPTER 59 +CM -A37 -FO3 REMOTE 58
+R1 -CP/CS CUSTOMER POWER/SIGNAL MANIPULATOR 143 +R1 -H1 EXT.LAMP MANIPULATOR 112
+R1 -CP/CS CUSTOMER POWER/SIGNAL MANIPULATOR 144 +R1 -H1 EXT.LAMP MANIPULATOR 122
+R1 -CP/CS CUSTOMER POWER/SIGNAL MANIPULATOR 153 +CM -I/O1 Green 60
+R1 -CP/CS CUSTOMER POWER/SIGNAL MANIPULATOR 179 +CM -A3 -IDEpwr1 IDE FLASH 53
+R1 -CP/CS CUSTOMER POWER/SIGNAL MANIPULATOR 180 +CM -A31 -J2 COM1 51
+R1 -CP/CS CUSTOMER PROFIBUS MANIPULATOR 181 +CM -A31 -J2 MC CONSOLE 51
+R1 -CP/CS CUSTOMER DEVICENET MANIPULATOR 181 +CM -A31 -J2 COM1 55
+R1 -CP/CS CUSTOMER INTERBUS MANIPULATOR 181 +CM -A3 -J4H1 COMPUTER UNIT 53
+R1 -CP/CS CUSTOMER POWER/SIGNAL/PROFIBUS MANIPULATOR 182 +CM -A31 -J6H1 MAIN COMPUTER 53
+R1 -CP/CS CUSTOMER POWER/SIGNAL/INTERBUS MANIPULATOR 183 +CM -A3 -J9H1 MAIN COMPUTER 54
+R1 -CP/CS CUSTOMER POWER/SIGNAL/DEVICENET MANIPULATOR 184 +CM -A3 -J9H2 MAIN COMPUTER 54
+R1 -CP/CS CUSTOMER POWER/SIGNAL/PROFIBUS MANIPULATOR 185 +CM -A31 -J9H3 MAIN COMPUTER 55
+R1 -CP/CS CUSTOMER POWER/SIGNAL/INTERBUS MANIPULATOR 186 +CM -A31 -J21 MAIN COMPUTER CHASSIS BLOWER 50
+R1 -CP/CS CUSTOMER POWER/SIGNAL/DEVICENET MANIPULATOR 187 +CM -A31 -LAN1 LAN MAIN COMPUTER 51
+R1 -CP/CS CUSTOMER POWER/SIGNAL MANIPULATOR 204 +CM -A31 -LAN1 LAN MAIN COMPUTER 55
+R1 -CS CUSTOMER SIGNAL MANIPULATOR 113 +CM -A33.1 -LAN1 PROFINET CONNECTIONS 57.1
+R1 -CS CUSTOMER SIGNAL MANIPULATOR 114 +R1 -MP MANIPULATOR POWER 132
+CM -DP1 DUAL PRESS 47 +R1 -MP MANIPULATOR POWER 201
+CM -DP1 DUAL PRESS 48 +R1 -MP 1-3 MANIPULATOR POWER 111
+DM -DP1 DUAL PRESS EXT.LAMP 172 +R1 -MP 1-3 MANIPULATOR POWER 121
+EXT -A21 -DP1 DUAL PRESS 43 +R1 -MP 4-6 MANIPULATOR POWER 111
+EXT -A21 -DP1 DUAL PRESS 44 +R1 -MP 4-6 MANIPULATOR POWER 121
+EXT -A21 -DP1 DUAL PRESS 45 +CM -G31 -P1 MOTHER BOARD POWER 53
+EXT -A21 -DP1 DUAL PRESS 46 +CM -G31 -PSU-X1 MOTHER BOARD POWER 53
+CM -DP2 DUAL PRESS 47 +CM -G31 -PSU-X2 MOTHER BOARD POWER 53
+CM -DP2 DUAL PRESS 48 +DM -BOX1 -R1.XP.SW23 POSITION SWITCH AND COOLING MANIPULATOR 177
+EXT -A21 -DP2 DUAL PRESS 43 +DM -BOX1 -R1FAN.SW23 MANIPULATOR COOLING FAN 177
+EXT -A21 -DP2 DUAL PRESS 44 +CM -S21.1.X1 3 MODE SELECTOR 39
+EXT -A21 -DP2 DUAL PRESS 45 +CM -S21.1.X1 2 MODE SELECTOR 42
+EXT -A21 -DP2 DUAL PRESS 46 +EXT -A21 -S21.1.X1 2 MODE SELECTOR EXT 43

Location: + CM
Plugs : =CAB+CM-A36-A1 Document no. Rev. Ind Page 13
Next 14
Prepared by, date: Approved by, date: Plugs overview
- =CAB+EXT-SLO.5-A21-S21.1.X1 3HAC024480-004 03 Total 153
Plug Plug
+R1 -SMB MEASUREMENT MANIPULATOR 132 +DM -E42 -X1 FAN UNIT 94
+R1 -SMB MEASUREMENT MANIPULATOR 162 +DM -G1 -X1 AC- input 85
+R1 -SMB MEASUREMENT MANIPULATOR 172 +DM -G1 -X1 AC-output 86
+R1 -SMB MEASUREMENT MANIPULATOR 202 +DM -G1 -X1 AC-input 87
+R2 -SMB MEASUREMENT MANIPULATOR 112 +CM -G2 -X1 AC-INPUT 33
+R2 -SMB MEASUREMENT MANIPULATOR 122 +DM -G2 -X1 DC INPUT 87
+R1 -SW POSITION SWITCHES MANIPULATOR 135 +CM -G3 -X1 ULTRA CAP 33
+R1 -SW POSITION SWITCHES MANIPULATOR 136 +DM -G3 -X1 ENERGY BANK 87
+R1 -SW POSITION SWITCHES MANIPULATOR 145 +CM -G4 -X1 CUSTOMER POWER SUPPLY 34
+R1 -SW POSITION SWITCHES MANIPULATOR 174 +CM -G6 -X1 DEVICENET POWER SUPPLY 34
+R1 -SW POSITION SWITCHES MANIPULATOR 203 +CM -G6 -X1 DEVICENET POWER SUPPLY 35
+R1 -SW23 POSITION SWITCHES 2/3 MANIPULATOR 175 +CM -G6 -X1 DEVICENET POWER SUPPLY 36
+R1 -SW23 POSITION SWITCHES 2/3 MANIPULATOR 176 +CM -G6 -X1 DEVICENET POWER SUPPLY 37
+R1 -SW23 POSITION SWITCHES 2/3, COOLING FAN MANIPULATOR 177 +CM -G7 -X1 CUSTOMER POWER SUPPLY 35
+R1 -SW23 POSITION SWITCHES 2/3, COOLING FAN MANIPULATOR 178 +CM -G8 -X1 CUSTOMER POWER SUPPLY 35
+CM -A31 -USB1 USB MAIN COMPUTER 51 +CM -G31 -X1 COMPUTER POWER SUPPLY 53
+CM -A31 -USB1 USB MAIN COMPUTER 55 +CM -I/Ox1 -X1 COMBI I/O UNIT OUTPUT CH 1-8 65
+CM -A31 -USB2 USB MAIN COMPUTER 51 +CM -I/Ox2 -X1 DIGITAL I/O UNIT OUTPUT CH 1-8 64
+CM -A31 -USB2 USB MAIN COMPUTER 55 +DM -K41.X1 -X1 K41 RELAY 85
+CM -A31 -USB3 USB3 55 +CM -RELAY I/O1 -X1 RELAY I/O UNIT OUTPUT CH 1-8 67
+CM -A31 -USB4 USB4 55 +CM -X2 PROFIBUS SLAVE 57
+CM -A3 -X1 COMPUTER UNIT 53 +CM -A21 -X2 RUN CHAIN 38
+CM -A21 -X1 RUN CHAIN 38 +CM -A21 -X2 PANEL BOARD EXT. CONN. 49
+CM -A21 -X1 PANEL BOARD EXT. CONN. 49 +EXT -A22 -X2 ADAPTER 43
+CM -A31 -X1 MAIN COMPUTER 50 +EXT -A22 -X2 ADAPTER 44
+CM -A33.1 -X1 PROFINET CONNECTIONS 57.1 +EXT -A22 -X2 ADAPTER 45
+CM -A34 -X1 COM2 RS232 61 +EXT -A22 -X2 ADAPTER 46
+CM -A35 -X1 DEVICENET ADAPTER 59 +CM -A23 -X2 STAUS LED ON DOOR 39
+CM -A37 -X1 INTERBUS M/S 58 +CM -A33.1 -X2 PROFINET CONNECTIONS 57.1
+CM -A37 -X1 REMOTE OUT 58 +CM -A34 -X2 COM3 RS232 61
+CM -A38.1 -X1 ETHERNET IP 52 +CM -A35 -X2 DEVICENET ADAPTER 60
+CM -A38.2 -X1 PROFIBUS SLAVE 52 +CM -A35 -X2 OPTION : DEVICE NET IRB 6600-7600 181
+CM -A38.3 -X1 ETHERNET IP 52 +CM -A37 -X2 INTERBUS SLAVE PART 58
+CM -A39 -X1 OPTION: SERIE CONVERTER 51 +CM -A37 -X2 REMOTE 58
+CM -A39 -X1 MAIN COMPUTER 55 +CM -A39 -X2 OPTION: SERIE CONVERTER 51
+DM -A41.1 -X1 Main servo drive unit 90 +CM -A39 -X2 OPTION: SERIE CONVERTER 55
+DM -A42 -X1 Axis computer power supply 90 +DM -A41.1 -X2 Main servo drive unit 93
+DM -A43 -X1 Panel board 88 +DM -A42 -X2 Axis computer board 90
+DM -A44 -X1 OPTION: Safe move Power supply 92.1 +CM -A61 -X2 OPTION: Remote service 73
+DM -A44 -X1 OPTION : EPS POWER SUPPLY 92 +CM -D31 -X2 SOLID STATE DRIVE 53
+CM -A61 -X1 Power supply Remote service 73 +CM -D32 -X2 SOLID STATE DRIVE 53
+CM -D31 -X1 SOLID STATE DRIVE 53 +DM -G1 -X2 DC- output 85
+CM -D32 -X1 SOLID STATE DRIVE 53 +DM -G1 -X2 DC- output 86
+CM -E2 -X1 EXT. COMPUTER FAN 39 +DM -G1 -X2 DC- output 87
+CM -E3 -X1 INTERNAL FAN 38 +CM -G2 -X2 24V SYS 24V COOL 33
+DM -E4 -X1 OPTION : INTERNAL FAN 88 +DM -G2 -X2 SIGNAL INPUT 87
+DM -E41 -X1 FAN UNIT 94 +CM -G4 -X2 POWER 24V DC CUSTOMER CONN. 34

Location: + CM
Plugs : =MAN+R1-1400-SMB Document no. Rev. Ind Page 14
Next 15
- =CAB.DC+CM-G4-X2 3HAC024480-004 03 Total 153
Plug Plug
+CM -G4 -X2 POWER 24V DC CUSTOMER CONN. 35 +CM -I/Ox1 -X5 DIGITAL I/O 66
+CM -G4 -X2 POWER 24V DC CUSTOMER CONN. 36 +CM -I/Ox1 -X5 ANALOGUE I/O 68
+CM -G4 -X2 POWER 24V DC CUSTOMER CONN. 37 +CM -I/Ox1 -X5 REMOTE I/O 69
+CM -G5 -X2 POWER 24V DC CUSTOMER CONN. 34 +CM -I/Ox1 -X5 INTERBUS SLAVE 70
+CM -G5 -X2 POWER 24V DC CUSTOMER CONN. 35 +CM -I/Ox1 -X5 PROFIBUS DP SLAVE 71
+CM -G5 -X2 POWER 24V DC CUSTOMER CONN. 37 +CM -I/Ox1 -X5 ENCODER UNIT 72
+CM -G6 -X2 POWER SUPPLY 24V DC DEVICENET 34 +CM -A21 -X6 SUPERIOR STOP 40
+CM -G6 -X2 POWER SUPPLY 24V DC DEVICENET 35 +CM -A21 -X6 PANEL BOARD EXT. CONN. 49
+CM -G6 -X2 POWER SUPPLY 24V DC DEVICENET 36 +DM -A42 -X6 Axis computer board 90
+CM -G6 -X2 POWER SUPPLY 24V DC DEVICENET 37 +DM -A43 -X6 Power for contactor unit 88
+CM -G7 -X2 POWER 24V DC CUSTOMER CONN. 35 +DM -A44 -X6 OPTION: Safe move 92.1
+CM -G8 -X2 POWER 24V DC CUSTOMER CONN. 35 +DM -A44 -X6 OPTION : EPS 92
+CM -I/Ox2 -X2 DIGITAL I/O UNIT OUTPUT CH 9-16 64 +DM -G2 -X6 24V SYS, COOL, PC 87
+DM -T1 -X2 TRANSFORMER UNIT 83 +CM -I/Ox1 -X6 COMBI I/O UNIT ANALOGUE PART 65
+DM -T1 -X2 TRANSFORMER UNIT 83 +CM -A21 -X7 RUN CHAIN 1 41
+CM -X3 PROFIBUS MASTER 57 +DM -A41.1 -X7 Main servo drive Signals to add axis 7 95
+CM -A21 -X3 GENERAL IN 39 +DM -A43 -X7 Drive power supply 88
+CM -A33.1 -X3 PROFINET CONNECTIONS 57.1 +DM -A44 -X7 OPTION: Safe move 92.1
+CM -A37 -X3 RS232 58 +DM -G2 -X7 ENERGY BANK 87
+DM -A41.1 -X3 Main servo drive unit 90 +CM -I/Ox1 -X7 ANALOGUE I/O OUTPUT CH 1-4 68
+DM -A43 -X3 Contactor connector 89 +CM -A21 -X8 RUN CHAIN 1 41
+DM -A44 -X3 OPTION: Safe move 92.1 +CM -A31 -X8 Blue PANELUNIT RS485 50
+DM -A44 -X3 OPTION : EPS 92 +CM -A32 -X8 Blue RS485 56
+DM -G1 -X3 DC- output 85 +DM -A41.1 -X8 Main servo drive Signals to add axis 8 96
+DM -G1 -X3 DC- output 86 +DM -A42 -X8 Axis computer board process I/O 91
+DM -G1 -X3 DC- output 87 +DM -A43 -X8 Contactor connector 89
+CM -G2 -X3 24V PC 33 +DM -A44 -X8 OPTION: Safe move 92.1
+DM -G2 -X3 24V SYS 87 +DM -G2 -X8 USB 87
+CM -I/Ox1 -X3 COMBI I/O AND DIG. I/O INPUT CH 1-9 63 +CM -I/Ox1 -X8 ANALOGUE I/O INPUT CH 1-4 68
+CM -I/Ox1 -X3 DIGITAL PART RELAY I/O UNIT INPUT CH 1-8 66 +CM -I/Ox1 -X8 REMOTE I/O IN 69
+CM -I/Ox1 -X3 INTERBUS SLAVE 70 +CM -A21 -X9 PANEL BOARD 39
+CM -I/Ox1 -X3 EXTERNAL SUPPLY 71 +CM -A21 -X9 PANEL BOARD 42
+CM -A21 -X4 GENERAL OUT 39 +CM -A21 -X9 PANEL BOARD 43
+CM -A37 -X4 24V DC 58 +CM -A21 -X9 PANEL BOARD 44
+DM -A42 -X4 Axis comp. Measurement 1 91 +CM -A21 -X9 PANEL BOARD 45
+DM -A43 -X4 Axis computer connector 88 +CM -A21 -X9 PANEL BOARD 46
+DM -A44 -X4 OPTION: Safe move 92.1 +EXT -A21 -X9 EXT.CONTROL PANEL 43
+DM -A44 -X4 OPTION : EPS 92 +EXT -A21 -X9 EXT.CONTROL PANEL 44
+DM -G1 -X4 Digital output 85 +EXT -A21 -X9 EXT.CONTROL PANEL 45
+DM -G1 -X4 Digital output 86 +EXT -A21 -X9 EXT.CONTROL PANEL 46
+CM -G2 -X4 ULTRA CAP 33 +DM -A41.1 -X9 Main sevo drive Signals to add axis 9 97
+DM -G2 -X4 24V I/O 87 +DM -A42 -X9 Axis computer board 90
+CM -I/Ox1 -X4 COMBI I/O AND DIG. I/O INPUT CH 9-16 63 +DM -A43 -X9 Contactor connector 89
+CM -A21 -X5 AUTO/GENERAL STOP 40 +DM -A44 -X9 OPTION: Safe move 92.2
+CM -A21 -X5 PANEL BOARD EXT. CONN. 49 +DM -A44 -X9 OPTION : EPS 92
+CM -A37 -X5 REMOTE IN 58 +DM -G2 -X9 DRIVE FAN 87
+CM -A37 -X5 OPTION : INTERBUS IRB 6600-6700 181 +CM -I/Ox1 -X9 REMOTE I/O OUT 69
+DM -A42 -X5 Axis comp. Measurement 2 91 +DM -X10 Connection of mains Q1/F6/Z1-T1 83
+DM -A43 -X5 PTC, 0V Brake 88 +CM -A21 -X10 PANEL BOARD 39
+DM -A43 -X5 PTC, 0V Brake 98 +CM -A21 -X10 PANEL BOARD 43
+DM -A44 -X5 OPTION: Safe move 92.1 +CM -A21 -X10 PANEL BOARD 44
+DM -A44 -X5 OPTION : EPS 92 +CM -A21 -X10 PANEL BOARD 45
+CM -G2 -X5 USB 33 +CM -A21 -X10 PANEL BOARD 46
+DM -G2 -X5 24V BRAKE / COOL 87 +EXT -A21 -X10 EXT. COTROL PANEL 43
+CM -I/Ox1 -X5 COMBI I/O AND DIG.I/O 63 +EXT -A21 -X10 EXT. COTROL PANEL 44

Location: + CM
Plugs : =CAB.DC+CM-G4-X2 Document no. Rev. Ind Page 15
Next 16
- =CAB+EXT-SLO.3-A21-X10 3HAC024480-004 03 Total 153
Plug Plug
+EXT -A21 -X10 EXT. CONTROL PANEL 45 +DM -A41.1 -X19 Main servo drive power connector 151
+EXT -A21 -X10 EXT. CONTROL PANEL 46 +CM -A21 -X20 RS485 39
+DM -A42 -X10 Axis computer power supply 90 +DM -A41.1.3 -X20 Single servo drive unit 7 95
+DM -A43 -X10 EXTERNAL FAN 88 +DM -A41.1.4 -X20 Single servo drive unit 8 96
+DM -A44 -X10 OPTION: Safe move 92.2 +DM -A41.1.5 -X20 Single servo drive 9 97
+CM -A61 -X10 Remote service, service 73 +CM -I/Ox1 -X20 INTERBUS SLAVE IN 70
+DM -A43 -X10.1 ADAPTER FAN 88 +CM -I/Ox1 -X20 PROFIBUS DP SLAVE 71
+DM -A43 -X10.2 ADAPTER FAN 88 +CM -I/Ox1 -X20 ENCODER UNIT 72
+CM -A21 -X11 ROBOT COMM.CARD 38 +DM -A41.1.3 -X21 Single servo Power to add axes 7 98
+DM -A41.1 -X11 Main servo drive power connector 161 +DM -A41.1.4 -X21 Single servo Power to add axes 8 99
+DM -A41.1 -X11 Main servo drive power connector 171 +DM -A41.1.5 -X21 Single servo Power to add axes 9 99
+DM -A41.1 -X11 Main servo drive power connector 201 +DM -A43 -X21 Limit switch robot 88
+DM -A42 -X11 Main servo drive axis comp. 90 +CM -I/Ox1 -X21 INTERBUS SLAVE OUT 70
+DM -A43 -X11 EXTERNAL FAN 88 +DM -X22 OPTION: SERVICE OUTLET 84
+DM -A44 -X11 OPTION: Safe move 92.2 +DM -A43 -X22 Limit switch external axes 88
+CM -A61 -X11 Remote service, service out 73 +DM -A43 -X22 Limit switch external axes 98
+CM -A21 -X12 PROCESS POWER SUPPLY 38 +CM -X23 SERVICE PORT ETHERNET 50
+DM -A41.1 -X12 Main servo drive power connector 161 +CM -X23 SERVICE PORT ETHERNET 73
+DM -A41.1 -X12 Main servo drive power connector 171 +DM -A43 -X23 Limit switch override 88
+DM -A41.1 -X12 Main servo drive power connector 201 +CM -X24 USB CONTROL MODULE 51
+DM -A43 -X12 Duty time connector 88 +CM -X24 USB CONTROL MODULE 55
+DM -A44 -X12 OPTION: Safe move 92.2 +DM -A43 -X24 PTC, Ext. customer connection 89
+DM -A41.1 -X13 Main servo drive power connector 161 +DM -A43 -X24 PTC, Ext. customer connector 98
+DM -A41.1 -X13 Main servo drive power connector 171 +DM -A41.2 -X30 Rectifier 93
+DM -A41.1 -X13 Main servo drive power connector 201 +DM -A41.2 -X31 Rectifier Capacitor connection 93
+DM -A44 -X13 OPTION: Safe move 92.1 +DM -A41.2 -X32 Rectifier Power supply 93
+CM -A21 -X14 RUN CHAIN 1 41 +DM -A41.2 -X33 Rectifier Bleeder connection 93
+DM -A41.1 -X14 Main servo drive power connector 161 +DM -A41.3 -X34 Capacitor unit 93
+DM -A41.1 -X14 Main servo drive power connector 171 +DM -XP0 Main connector 82
+DM -A41.1 -X14 Main servo drive power connector 201 +CM -XP4 OPTION : FPU-PLUG 47
+CM -A21 -X15 PANEL BOARD 39 +CM -XP4 OPTION: FPU-PLUG 48
+DM -A41.1 -X15 Main servo drive power connector 161 +CM -XP28 OPTION : EXTERN LAN 51
+DM -A41.1 -X15 Main servo drive power connector 171 +DM -XP40 Control cable and ext. axes 98
+DM -A41.1 -X15 Main servo drive power connector 201 +CM -XP/XT5 Customer signals terminal 113
+CM -A61 -X15 Remote service console 73 +CM -XP/XT5 Customer signals terminal 114
+CM -A21 -X17 RUN CHAIN 1 41 +CM -XP/XT5 Customer signals terminal 134
+DM -A41.1 -X17 Main servo drive unit power supply 111 +CM -XP/XT5.1 Customer signals terminal 143
+DM -A41.1 -X17 Main servo drive power connector 121 +CM -XP/XT5.1 Customer signals terminal 144
+CM -X18 OPTION: Remote service 73 +CM -XP/XT5.1 Customer signals terminal 164
+CM -A21 -X18 PANEL BOARD 39 +CM -XP/XT5.1 Customer signals terminal 179
+CM -E2 -X18 EXT. COMPUTER FAN 39 +CM -XP/XT5.1 Customer signals terminal 185

Location: + CM
Plugs : =CAB+EXT-SLO.4-A21-X10 Document no. Rev. Ind Page 16
Next 17
- =CAB.DC+CM-1600-XP/XT5.2 3HAC024480-004 03 Total 153
Plug Plug
+CM -XP/XT5.2 Customer signals terminal 144 +CM -XS4 FLEXPENDANT 47
+CM -XP/XT5.2 Customer signals terminal 153 +CM -XS4 FLEXPENDANT 48
+CM -XP/XT5.2 Customer signals terminal 154 +EXT -A21 -XS4 EXT.CONTROL PANEL 43
+CM -XP/XT5.2 Customer signals terminal 180 +CM -XS6 Customer signals terminal 204
+CM -XP/XT5.2 Customer signals terminal 182 +CM -XS8 Position switch connector 203
+CM -XP/XT5.2 Customer signals terminal 183 +CM -XS17 OPTION : DEVICE NET 59
+CM -XP/XT5.2 Customer signals terminal 184 +DM -XS40 Control cable and ext. axes 98
+CM -XP/XT5.2 Customer signals terminal 185 +DM -XS41 Ext. axis signal 91
+CM -XP/XT5.2 Customer signals terminal 186 +DM -XS/XP1 Robot power connector 111
+CM -XP/XT5.3 Customer signals terminal 186 +DM -XS/XP2 Robot signal connector 112
+CM -XP/XT5.3 Customer signals terminal 187 +DM -XS/XP2 Robot signal connector 122
+CM -XP/XT6 Customer power terminal 143 +DM -XS/XP2 Robot signal connector 132
+CM -XP/XT6 Customer power terminal 179 +CM -XS/XP3 PANEL BOARD 49
+CM -XP/XT6 Customer power terminal 180 +CM -XS/XP5 Customer power/signals connector 113
+CM -XP/XT6 Customer power terminal 183 +CM -XS/XP5 Customer signals connector 123
+CM -XP/XT6 Customer power terminal 184 +CM -XS/XP5 Customer signals connector 124
+CM -XP/XT6 Customer power terminal 185 +CM -XS/XP5 Costomer signals connections 133
+CM -XP/XT6 Customer power terminal 186 +CM -XS/XP5 Costomer signals connections 134
+CM -XP/XT8 Position switch terminal 135 +CM -XS/XP5 Customer power/signals connector 153
+CM -XP/XT8 Position switch terminal 136 +CM -XS/XP5 Customer power/signals connector 154
+CM -XP/XT8 Position switch terminal 145 +CM -XS/XP5 Customer power/signal connector 163
+CM -XP/XT8 Position switch terminal 146 +CM -XS/XP5 Customer power/signal connector 164
+CM -XP/XT8 Position switch terminal 155 +DM -XS/XP7 External axes connector 98
+CM -XP/XT8 Position switch terminal 156 +DM -XS/XP7 External axes connector 99
+CM -XP/XT8 Position switch terminal 165 +CM -XS/XP8 Position switch connector 135
+CM -XP/XT8 Position switch terminal 166 +CM -XS/XP8 Position switch connector 136
+CM -XP/XT8.1 Position switch terminal 173 +CM -XS/XP8 Position switch connector 145
+CM -XP/XT58.1 Position switch axes 2-3 terminal 175 +CM -XS/XP8 Position switch connector 173
+CM -XP/XT58.1 Position switch axes 2-3 terminal 176 +CM -XS/XP8 Position switch connector 174
+CM -XP/XT58.2 Position switch axes 2-3 terminal 175 +CM -XS/XP13 Customer power/signals 179
+CM -XP/XT58.2 Position switch axes 2-3 terminal 176 +CM -XS/XP13 Customer power/signals 180
+DM -E1 -XS1 Fan connector 94 +CM -XS/XP13 Customer power/signals Profibus 181

Location: + CM
Plugs : =CAB.SC+CM-1600-XP/XT5.2 Document no. Rev. Ind Page 17
Next 18
- =CAB+CM-XS/XP13 3HAC024480-004 03 Total 153
Plug Plug
+CM -XS/XP13 Customer power/signals Devicenet 181
+CM -XS/XP13 Customer power/signals Interbus 181
+CM -XS/XP13 Customer power/signals Profibus 182
+CM -XS/XP13 Customer power/signals Devicenet 184
+CM -XS/XP13 Customer power/signals Profibus 185
+CM -XS/XP13 Customer power/signals DeviceNet 187
+DM -XS/XP40 Control cable and ext. axes 89
+CM -XS/XP58 Position switch axes 2-3 175
+CM -XS/XP58 Position switch axes 2-3 176
+DM -XS/XP58 Position switch axes 2-3 178
+CM -XT16 CROSS CONNECTION 230V 32
+DM -XT16 CROSS CONNECTION 230V 86
+DM -XT16 CROSS CONNECTION 230V 87
+CM -XT31 TERMINAL FOR 24V I/O 35

Location: + CM
Plugs : =CAB+CM-XS/XP13 Document no. Rev. Ind Page 18
Next 20
- =CAB.SC+CM-SLO.1-XT31 03 Total 153
1 2 3 4 5 6 7 8
FRONT FRONT VIEW INSIDE DOOR

PANEL
NEW COMPUTER OLD COMPUTER AC/BD

A31 DSQC639 A3 (A31 DSQC623, G31, A32 DSQC602)
G4 G5
Q1
E3
S21.3
XT5.3
XT8.1
XT8.2
XT6
S21.2
G3
XT58.1
XT58.2
XT5.1
XT5.2
S21.1
X24
G2
S22
X23
XS4
X2
I/O1
XT31
I/O2
I/O3
I/O4
X3
P1 G1
A41
X22 X1
XT16
F2
F1
XS41
XS9 X8
XS5/XS13
X4
X9 XS2
XS3
STATUS X7
G2 LED
LABEL
X6 X58 XP28
X5 XS17
XP0 XS1 XS7
X3
X1
X8 X2
Latest revision: Lab/Office: Status: 2008-07-17 Plant: = CAB.SC

CONTROL SYS. IRC5 M2004 DESIGN 06 Location: + CM
FRONT VIEW OF SINGLE CABINET Approved
Sublocation: +
Next 21
1 2 3 4 5 6 7 8
LEFT VIEW WITH LEFT VIEW RIGHT VIEW

FLANGE DISCONNECT
Q1
Q1 A21
E2
G6
G6 F6
E1
Z1 A42
F4
K42
K43
R1
K44 F5
T1
A43
Z2 E4 A44

SIDE VIEWS OF SINGLE CABINET Approved
Sublocation: +
Next 22
1 2 3 4 5 6 7 8
LEFT FRONT FRONT RIGHT

VIEW PANEL VIEW VIEW
NEW COMPUTER OLD COMPUTER AC/BD

A31 DSQC639 A3 (A31 DSQC623, G31, A32 DSQC602)
Q2 Q2
XT16
A21
E2
S21.3
S21.2 G2
G6 G8
S21.1 G3
G4 G5 G7
X23 X24
I/O6 I/O5 I/O4 I/O2 I/O1 I/O3
XT31
(FLOOR MOUNTED)
XP28
X8
XS5/XS13
S22
XS3
X58
XS4
XS17
Latest revision: Lab/Office: Status: 2008-07-17 Plant: = CAB.DC

VIEW OF CONTROL MODULE Approved
Sublocation: +
DUAL CABINET
Next 23
1 2 3 4 5 6 7 8
J21
PANEL MAIN
UNIT
X8 COMPUTER
TPU AXC1 WRIST
LABEL CONSOLE A8 A9 STATUS BAND A31

DIOD ESD
DSQC639 FAN
E22
LAN USB2 FIELD

MEMORY COM1 SERVICE
CARD USB1
BUS A33 Profibus DP M/S
A8
ADAPTER
A38
A33.1 ProfiNet
A34 Dual RS232
A35 Devicenet
A36 Ethernet
A37 Interbus M/S PCI-SLOTS
RL1 RL2 X4 X3
X12
PANEL
BOARD X20 X5
X7 X8
A21
X6
X15 RL3
X11 X14 X17
X18
X1
X10
RL4
X9 X2
VIEW OF COMPUTER UNIT Approved
Sublocation: +
AND PANEL BOARD
Next 24
1 2 3 4 5 6 7 8
LEFT FRONT FRONT RIGHT

VIEW PANEL VIEW VIEW
F6
ROOF-MOUNTED
Q1
Q1
E1
A42
Z1 H1
F4 P1 G1
K43
K42
K44 F5
X22
A41
R1
T1
K41
A43 F2
F1 A44
XS41
XS2
XP0 XS1 XS7

CONTROL SYS. IRC5 M2004 DESIGN 06 Location: + DM
VIEW OF DRIVE MODULE Approved
Sublocation: +
DUAL CABINET
Next 25
1 2 3 4 5 6 7 8
A42 Axis computer unit
A43 Contactor unit
X7 X5 X9 X11 X6 X4
X8
X9
X22
X2
X21 X3
X8
X23
X24 X11
X5
X1 X10 X12
X4
X10 X6
X1

VIEW OF CONTACTOR UNIT AND Approved
Sublocation: +
AXIS COMPUTER UNIT
Next 26
1 2 3 4 5 6 7 8
3 UNITS FOR IRB140, IRB1400, IRB1600, IRB2400, IRB340 6 UNITS FOR IRB4400, IRB940, IRB6600, IRB7600
A41.1.4
SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 8
A41.1.3
DC-BUSBAR SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 7
A41.3 A41.3
CAPACITOR CAPACITOR
UNIT UNIT
A41.2
A41.2
RECTIFIER
RECTIFIER
A41.1
MAIN SERVO
DRIVE UNIT
A41.1.3 DC-BUSBAR
OPTION: EXT AXIS 7
A41.1
A41.1.4 MIAN SERVO DRIVE UNIT
OPTION: EXT AXIS 8
DC-BUSBAR
A41.1.5
OPTION: EXT AXIS 9

VIEW OF DRIVE UNIT VARIANTS Approved
Sublocation: +
Next 30
1 2 3 4 5 6 7 8
Control module = CM
CAB = Common cabinet
Plant = CAB.DC = Dual cabinet
CAB.SC = Single cabinet
Location + CM
Sublocation = SLO.1 or SLO.2 etc. shows that the sheet is a variant of the CM.

CONTROL MODULE Approved
Sublocation: +
Next 31
1 2 3 4 5 6 7 8
230V
230V
Q2
XT16
G3 G2
Option Option Option
AC Devicenet PS Customer PS Customer PS
Option Ultra cap
Service outlet G6 G4 G5
DC
AC AC AC
DC DC DC
F5
A21 A31
Panel Computer
module
F4 board
Earth
fault
prot.
S21 I/Ox
Control I/O
FPU
Ethernet service
X22 panel unit
Service
Field bus
outlet
Drive
Drive
USB
LAN
Customer Customer
connection connection

BLOCK DIAGRAM CM Approved
Sublocation: +
Next 32
Latest revision:
1
Prepared by, date:

-XT16
L1
L1
/33.4 / 230V AC1;1 -152 AWG16 BK
L1
/35.7 /34.2 / 230V AC1;2
L1
2
/35.1 /34.5 / 230V AC1;3
L1
/35.3 /34.7 / 230V AC1;4
CROSS CONNECTION 230V
L1
Approved by, date:

/35.4 / 230V AC1;5
L1
MAIN SWITCH
JUMPER
/35.6 / 230V AC1;6 -Q2
L1
-173 AWG16 BK 230V AC1_DM / /85.7
L1
L1
T1
-174 AWG16 BK 230V AC2_DM / /85.7
L2
L2
T2
/33.4 / 230V AC2;1 -153 AWG16 BK

3
L2
L3
T3
/35.7 /34.2 / 230V AC2;2
L2
/35.1 /34.5 / 230V AC2;3 GND_DM / /85.7
L2
JUMPER
/35.3 /34.7 / 230V AC2;4
L2
/35.4 / 230V AC2;5
L2
/35.6 / 230V AC2;6

L2
L2
4
L2
Lab/Office:
5
6
MAINS CONNECTION DUAL CABINET

CONTROL SYS. IRC5 M2004 DESIGN 06
Status:
7
Document no.
Approved
Plant: 2008-07-17
Location:
3HAC024480-004
Sublocation: +
+ CM
8
03
= CAB.DC
Next 33
Rev. Ind Page 32
Total 153
Latest revision:
1
-G2
Prepared by, date:

-X2
/38.2 / 24V SYS -250 AWG18
1
PROCESS POWER SUPPLY
/38.2 / 0V SYS -251 AWG18
2
2
/38.2 / 24V COOL -252 AWG18
PANEL BOARD
24V COOL
24V SYS
/38.2 / 0V COOL -253 AWG18
Approved by, date:

FOR SINGLE CABINET
5
230V AC1;3 / /86.7
6
230V AC2;3 / /86.8
-X3
/50.2 / 24V PC;1 -301 AWG18
3
1
/50.2 / 24V PC;2 -302 AWG18
UNIT
AWG18
24V PC
/50.2 / 0V PC;1 -303
COMPUTER
3
/50.2 / 0V PC;2 -304 AWG18
4
-X1
230V AC1;1 / /32.2

1
230V AC2;1 / /32.3

5
AC -INPUT
FOR DUAL CABINET
4
-G3
-X1
-X4
+
AWG16 gnye
1
1
+
2
2
NC
Lab/Office:
3
3
NC
4
4
+
5
5
5
ULTRA CAP
6
6
-
7
7
ULTRA CAP
8
8
+Sense
9
9
NC
-
10
10

6
-X5
/51.6 / USB2 +5V AWG24

1
2/RD
/51.6 / USB2 D- AWG28

2
MAIN
USB
/51.6 / USB2 D+ AWG28

3
COMPUTER
Status:
1/WH 1/GN
/51.6 / USB2_GND AWG24

7
2/BK
Document no.
Approved
Plant: 2008-07-17
Location:
3HAC024480-004
Sublocation: +
+ CM
8
03
= CAB
Rev. Ind
Next 34
Page 33
Total 153
-G6
Latest revision:
1
Prepared by, date:

POWER
SUPPLY
DEVICENET
-X2
-X1
/60.2 / +24Vdevicenet;1 -704 AWG20 BU -308 AWG16 BK 230V AC1;2 / /32.2
AC
L
+
-309 AWG16 BK 230V AC2;2 / /32.3
DC
-
N
2
+
/60.2 / 0Vdevicenet;1 -703 AWG20 BU
Approved by, date:

/63.2 / +24Vdevicenet;2 AWG16 GNYE
/63.2 / 0Vdevicenet;2
GND
/66.2 / +24Vdevicenet;3
3
4
-G4
Lab/Office:
/73.2 / 24V Res
POWER
/73.2 / 0V ReS
SUPPLY
CUSTOMER
-X1
5
-X2
24V I/O -_152 AWG16 BK 230V AC1;3 / /32.2

AC
1
0V I/O -_153 AWG16 BK 230V AC2;3 / /32.3

DC
-
5
AWG16 GNYE
3
FOR DUAL CABINET

Customer
Connection
24V I/O
+
OPTION: POWER SUPPLY

0V I/O
-
6
-G5

POWER
SUPPLY
CUSTOMER
-X2
-X1
Status:
24V I/O -181 AWG16 BK 230V AC1;4 / /32.2

7
AC
1
Document no.
Approved
0V I/O -182 AWG16 BK 230V AC2;4 / /32.3

DC
-
5
2008-07-17
AWG16 GNYE
3
Customer
Connection
Plant:
24V I/O
Location:
+
3HAC024480-004
0V I/O
-
Sublocation: +
+ CM
8
03
= CAB.DC
Next 35
Rev. Ind Page 34
Total 153
-G4
Latest revision:
1
Prepared by, date:

POWER
SUPPLY
-X2
-X1
CUSTOMER
-147 AWG16 BU -157 AWG16 BK 230V AC1;3 / /32.2
AC
24
AC
-158 AWG16 BK 230V AC2;3 / /32.3
DC
24
AC
-148 AWG16 BU
0
AWG16 GNYE
0
GND
2
-G5
Approved by, date:

POWER
SUPPLY
CUSTOMER
-X2
-X1
-147 AWG16 BU -157 AWG16 BK 230V AC1;4 / /32.2

AC
24
AC
-158 AWG16 BK 230V AC2;4 / /32.3
-XT31
TERMINAL FOR 24V I/O
DC
24
AC
-148 AWG16 BU
3
1
0
AWG16 GNYE
2
0
GND
5
6
-G7
Customer
Connection
4
POWER
SUPPLY
7
CUSTOMER
4
8
-X2
-X1
-147 AWG16 BU -_157 AWG16 BK 230V AC1;5 / /32.2

AC
24
AC
9
-_158 AWG16 BK 230V AC2;5 / /32.4
DC
24
AC
10
-148 AWG16 BU
0
AWG16 GNYE
Lab/Office:
0
GND
5
-G8
-703
-704
POWER
SUPPLY
CUSTOMER
-X2
-X1
-193 AWG16 BU -145 AWG16 BK 230V AC1;6 / /32.3

AC
24
AC
AWG20 BU
AWG20 BU
FOR DUAL CABINET

/60.2 / +24Vdevicenet;1 -146 AWG16 BK 230V AC2;6 / /32.4
DC
24
AC

0
6
AWG16 GNYE
0
GND
OPTION: POWER SUPPLY DSQC 609
-G6
POWER
SUPPLY
Status:
DEVICENET
7
-X2
-X1
Document no.
Approved
/69.2 / 0Vdevicenet;5 -193 AWG16 BU -145 AWG16 BK 230V AC1;2 / /32.2

L
+
AC
AWG16 BK
2008-07-17
-146 230V AC2;2 / /32.3

+
DC
N
-
AWG16 GNYE
-
Plant:
GND
Location:
3HAC024480-004
+ CM
8
03
Sublocation: + SLO.1
= CAB.DC
/73.2 / 24V Res

Next 36
Rev. Ind Page 35
/73.2 / 0V ReS
Total 153
-G6
Latest revision:
1
Prepared by, date:

POWER
SUPPLY
DEVICENET
-X2
-X1
230V AC1;2 / /86.6
AC
L
+
230V AC2;2 / /86.8
DC
-
N
2
+
-
Approved by, date:

AWG16
gnye
GND
3
-G4
POWER
SUPPLY
CUSTOMER
-X1
-X2
230V AC1;1 / /86.6

AC
1
+
4
230V AC2;1 / /86.7

DC
-
5
+
3
Lab/Office:
5
/60.2 / +24Vdevicenet;1 -704 AWG20 BU
FOR SINGLE CABINET

OPTION: POWER SUPPLY /63.2 / 0Vdevicenet;2
6
-XT31
2A
2
1
/68.2 / +24Vdevicenet;4 704

2A
4
3
Status:
703
6
5
7
8
7
Document no.
Approved
704 -297 AWG16 BU
9
2008-07-17
/71.2 / +24Vdevicenet;7 703 -298 AWG16 BU

10
Plant:
Location:
3HAC024480-004
Sublocation: +
/73.2 / 24V Res

+ CM
8
03
/73.2 / 0V ReS
= CAB.SC
Next 37
Rev. Ind Page 36
Total 153
-XT31
Latest revision:
1
24V I/O;1 / /87.2
Prepared by, date:

1
2
3
4
0V I/O;1 / /87.2
Customer
Connection
6
-G4
7
2
8
POWER
SUPPLY
Approved by, date:

9
CUSTOMER
-X2
-X1
-295 AWG16 BU 230V AC1;12 / /87.6

AC
10
24
AC
230V AC2;12 / /87.5

DC
24
AC
-296 AWG16 BU
-703
-704
0
AWG16 GNYE
GND
0
3
AWG20 BU
AWG20 BU
TERMINAL FOR 24V I/O

-G5
POWER
SUPPLY
CUSTOMER
-X2
-X1
-_295 AWG16 BU
4
230V AC1;13 / /87.6

AC
24
AC
/66.2 / 0Vdevicenet;3 230V AC2;13 / /87.5
DC
24
AC
-_296 AWG16 BU
0
/68.2 / +24Vdevicenet;4 AWG16 GNYE

GND
Lab/Office:
5
FOR SINGLE CABINET /73.2 / 24V Res

6
/73.2 / 0V ReS
OPTION: POWER SUPPLY DSQC 609
Status:
7
Document no.
Approved
-G6
2008-07-17
POWER
SUPPLY
DEVICENET
Plant:
-X2
-X1
-297 AWG16 BU 230V AC1;11 / /87.6

L
Location:
AC
3HAC024480-004
230V AC2;11 / /87.5

+
DC
N
-298 AWG16 BU
+ CM
-
8
03
AWG16 gnye
= CAB.SC
-
GND
Next 38
Rev. Ind Page 37
Total 153
1 2 3 4 5 6 7 8
PANEL BOARD
-A21
-X12 24V FPU POWER
/33.2 /87.4 / 24V SYS 24V SYS
1 24V PANEL
/33.2 /87.5 / 0V SYS 0V SYS
2
24V PANEL
/33.2 /87.4 / 24V COOL
3
/33.2 /87.5 / 0V COOL
4
INTERNAL -X1 -X10 -209

ES1 top AWG20 BU ES FPU 1:A / /47.2 /48.2
FAN
JUMPER
3 5
-X2 -211
ES2 top AWG20 BU ES FPU 2:A / /47.2 /48.2 FPU
-E3
JUMPER
3 7
AWG20 BU
AWG20 BU
M -212 AWG20 BU ES FPU 2:B / /47.2 /48.2

8
2 1 EXTERNAL 0V 0V -210 AWG20 BU ES FPU 1:B / /47.2 /48.2
-364
-363
EMERGENCY 24V Panel 4 24V PANEL 6

4
2 1 STOP PB
RunCh0V
RunCh+
Run CH1 top

Run CH2 top 5 EMERGENCY PB

-S21.3
5
-X9 -237
EMERGENCY ES1OUT:A AWG20 21 22
STOP OUTPUT 1 ES2 OUT:A 1 17 -238 AWG20

1 18 -233 AWG20 11 12
EMERGENCY ES2 OUT:B 13 -234 AWG20
STOP OUTPUT 2 ES1OUT:B 2 14 -231 AWG20
2 11 -232 AWG20
OPTION: Sep ES2:A RunCh0V 12 -235 AWG20
EXTERNAL Sep ES1:A 9 RunCh+ 15 -236 AWG20
CONNECTIONS 9 -ES2 16
-ES1
JUMPER
JUMPER
SEE PAGE 49
U U
Sep ES1:B
10
Sep ES2:B
10
ES2 bottom
EXTERNAL ES1 bottom AWG24
JUMPER
JUMPER
7
-X11
SUPPLY 0V 7
24V Panel 8 1
8 2 WHGN 24V_Sig.ref. / /50.7
SOFT_ESO
24V PANEL 3 BU RS485+ / /50.7
SOFT_ESI 4 WHBU RS485- / /50.7 MAIN
0V 5 COMPUTER
6 WHBN 0V_Sig.ref. / /50.7
ES1:int 7
EMERGENCY STOP
/40.6 / RunCh+
/40.5 / RunCh_0V
/40.6 / RCH2
/40.7 / RCH1
6 8
RELAY SIGNALS ES2:int
6 ES1 ES2

EMERGENCY STOP Approved
Sublocation: +
Next 39
1 2 3 4 5 6 7 8
PANEL BOARD
-A21
X3 and X4 -X10
only in DSQC 630 24V SYS 24V FPU POWER -205 AWG20 BU 24V FPU POWER / /47.2 /48.2
24V PANEL 1
-X3 -206
General in1 0V SYS AWG20 BU 0V PANELB / /47.2 /48.2
1 General in2 2
2 General in3 -207 AWG20 BU EN1_1 / /47.2 /48.2 FPU
3 General in4 3
4 General in5 -208 AWG20 BU EN1_2 / /47.2 /48.2
5 General in6 4
6 General in7 -213 AWG20 BU FPU START / /47.2 /48.2
7 General in8 9
8 0V
9 +24V
10 OPTION:
-X6 OPTION
EN1_1A EXTERNAL
-X4
General out1 7 EN1_1B EXTERNAL CONNECTIONS 2 4 6 8
1 General out2 8 EN2_1B ENABLE DEVICE SEE PAGE 49 -S21.1.X1 3 1 7 5
2 General out3 9 EN2_1A
3 General out4 10
OPTION:STATUS 4 General out5 -X9
-245
-244
-243
-246
-241
-240
-239
-242
LED ON FRONT 5 General out6 -227 AWG20 BU
-A23 6 8 -226 AWG20 BU
General out7
7 General out8 7 -225 AWG20 BU
-223
AWG20 BU
EXT.AUTO 2
EXT.MAN 2
EXT MAN FS 2
EXT.COMMON 2
EXT.AUTO 1
EXT.MAN 1
EXT MAN FS 1
EXT.COMMON 1
8 0V 6
9 4 -222 AWG20 BU
-ES2 -221 AWG20 BU
3
2
-ES1 3-MODE
-X2 AWG26 SELECTOR
-SUP_ST2 WHOG
-X20 -S21.1
6 12 10 2 4 8 18 22 24 14 16 20
1 OG 1 >1
-SUP_ST1
2 BU 2 RS485+ 5 1 17 13
4 WHBU 4 RS485-
-GS2 -220
5 WHGN 5 24V DC AWG20 BU
3 GN 3 1 -224 AWG20 BU
-GS1
6 WHBN 6 0V 5
7 BN 7
-AS2
8 8
MOTOR ON PB
/40.5 / EN1
/40.5 / EN2
/40.5 / MAN1
/40.4 / MAN2
/41.3 / SPEED
-AS1 -S21.2
-229 AWG20 BU 14 13
-ENABLE1 -228 AWG20 BU
10
9
-230 AWG20 BU X2 X1
19
EXT.COMPUTER FAN
24V PANEL
-X15 -E2
OP_COM
-X18 -E2 -X18 -X1
OP_MAN 1
3 24V COOL -361 AWG20 BU RD
+
2 2 1
OP_AUTO TACHO -362 AWG20 BU BN
M
OP_MAN_FS 2 3 3 2
4 -
FAN 0V -360 AWG20 BU BK
1 1 3

RUN CHAIN OPERATING Approved
Sublocation: +
MODE SELECTOR, 3 MODES
Next 40
1 2 3 4 5 6 7 8
PANEL BOARD
-A21
24V SYS 24V FPU POWER
24V PANEL
0V SYS
RunCh_0V / /38.5
RunCh+ / /38.5
24V PANEL
-X5
MAN2 / /39.4
MAN1 / /39.4
RCH2 / /38.6
RCH1 / /38.6
JUMPER 24V PANEL
EN2 / /39.4
EN1 / /39.4
JUMPER 12 24V PANEL
JUMPER 6 0V
JUMPER 7 0V
1
-X5
AS1+
11 AS1
AUTO AS1
STOP &
AS1-
AS2+ 9 AS2 SOFT AS
OPTION: 5
EXTERNAL AS2
CONNECTIONS
SEE PAGE 49
AS2-
GS1+ 3 GS1
10
GS1
GENERAL &
STOP
GS1- SOFT GS
GS2+ 8 GS2 CH2 CH1
4
GS2
GS2-
2
-X6
JUMPER 24V PANEL
JUMPER 6 0V
1
/41.4 / RCH2
/41.4 / RCH1
SS1+ SS1
4
/41.3 / ENABLE2_1
/41.3 / ENABLE2_2
/41.3 / ENABLE2_3
/41.3 / ENABLE2_4
SUPERIOR SS1
STOP
SS1- SOFT SS
SS2+ 2 SS2
5
SS2
SS2-
3

Sublocation: +
Next 41
1 2 3 4 5 6 7 8
CONTROL
PANEL BOARD
MODULE
-A21
/40.7 / RCH1
/40.6 / RCH2
-X7
RUN CH1 RUN_CH1 / /88.2
0V 1 RUN CH1Ret RUN_CH1Ret / /88.2
2
RUN CH2Ret RUN_CH2Ret / /88.2 Drive
24V PANEL 4 RUN CH2 RUN_CH2 / /88.2 module1
/39.4 / SPEED 3 SPEED SPEED / /88.2 A43.X1
5 0V 0V / /88.2
AND
/40.5 / ENABLE2_1 6 ENABLE2_1 ENABLE2_1 / /88.2
7 ENABLE2_1Ret ENABLE2_1Ret / /88.2 K41.X1
/40.5 / ENABLE2_2 8 AC_ON1 AC_ON1 / /85.7
9 0V 0V;1 / /85.7
/40.5 / ENABLE2_3 10
/40.5 / ENABLE2_4
-X8
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret
24V PANEL 4 RUN CH2 BU
3 SPEED
5 0V if not used Drive
6 ENABLE2_2 module2
7 ENABLE2_2Ret BU
A43.X1
8 AC_ON1 if not used
9 0V
10
-X14
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret
3 SPEED Drive
5 0V if not used module3
6 ENABLE2_3
A43.X1
7 ENABLE2_3Ret BU
9 0V
10
-X17
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret
3 SPEED Drive
5 0V if not used module4
6 ENABLE2_4
A43.X1
7 ENABLE2_4Ret BU
9 0V
10

RUN CHAIN Approved
Sublocation: +
Next 42
1 2 3 4 5 6 7 8
PANEL BOARD
-A21
-X9 -S21.1.X1
-222 AWG20 BU MAN2 -241 OG EXT.AUTO1
3 7
-221 AWG20 BU AUTO2 -240 OG EXT.MAN1
2 6
7 3
-225 AWG20 BU AUTO1 -244 OG EXT.MAN2 OPTION
6 2
2-MODE
SELECTOR
1
-S21.1
1 3 5 7 9 11 13 15
2 6 10 14
5
-224 AWG20 BU 0V -246 OG EXT.COMMON2
5 4
-220 AWG20 BU 24V panel -242 OG EXT.COMMON1
1 8
MOTOR ON PB
-S21.2
-229 AWG20 BU MOTON 14 13

10
-228 AWG20 BU 24V PANEL
9
-230 AWG20 BU MONLMP X2 X1
19

Next 43
1 2 3 4 5 6 7 8
CONTROL
MODULE
PANEL BOARD EXT.CONTROL PANEL
-A21 +EXT-A21
-X9 -X9 -S21.1.X1
-222 AWG20 -241 EXT.AUTO1
3 3 -221 AWG20 -240 EXT.MAN1 7
2 2 -226 AWG20 -245 EXT.AUTO2 6
7 7 -225 AWG20 -244 EXT.MAN2 3
6 6 2
2-MODE SELECTOR
-S21.1 1 3 5 7 9 11 13 15 OPTION
2 6 10 14
-224 AWG20 -246 EXT.COMMON2

5 5 -220 AWG20 -242 EXT.COMMON1 4
1 1 8
MOTOR ON PB
-S21.2
-229 AWG20 14 13
10 10
-230 AWG20 X2 X1
19 19 -228 AWG20
9 9
EMERGENCY PB
-S21.3
-501 -237 ES panel 1:A 21 22
17 -502 17 -238 ES panel 1:A
18 -498 18 -233 ES panel 2:A 11 12
13 -499 13 -234 ES panel 2:A
14 14 -231 ES panel 2:B
11 11 -232 ES panel 2:B
12 12 -235 ES panel 1:B
15 15 -236 ES panel 1:B
16 16
1 1
2 2
2 2
-X10 1 1 -X10 -XS4

BN/BK 24V TPU -205 24V FPU_POWER
1 BN/RD 0V 1 -206 0V 1
2 BN/OG EN1 2 -207 EN 1_1 2
3 BN/YE EN2 3 -208 EN 1_2 7
4 -496 4 -209 ES FPU 1:A 17
5 -500 5 -210 ES FPU 1:B 3
6 -495 6 -211 ES FPU 2:A 4 FPU
7 -497 7 -212 ES FPU 2:B 5
8 BN/GN TPU_START 8 -213 FPU_START 6
9 9 0V 11
EN2 8
12
-A22 ADAPTER -A32.A8
MAIN /50.6 / TD+ AWG24 TD+ -X2 TD+
COMPUTER /50.6 / TD- TD- 1 TD- 13
A31-A8 /50.6 / RD+ RD+ 2 RD+ 14

/50.6 / RD- RD- 3 RD- 15
6 16

RUN CHAIN EXT OPERATING Approved
Next 44
1 2 3 4 5 6 7 8
CONTROL
MODULE
-A21 +EXT-A21
-X9 -X9 -S21.1.X1
3 3 -221 AWG20 -240 EXT.MAN1 7
2 2 -226 AWG20 -245 EXT.AUTO2 6
7 7 -225 AWG20 -244 EXT.MAN2 3
6 6 2
2-MODE SELECTOR
-S21.1 1 3 5 7 9 11 13 15 OPTION
2 6 10 14

5 5 -220 AWG20 -242 EXT.COMMON1 4
1 1 8
MOTOR ON PB
-S21.2
-229 AWG20 14 13
10 10
-230 AWG20 X2 X1
19 19 -228 AWG20
9 9
EMERGENCY PB
-S21.3
-501 -237 ES panel 1:A 21 22
17 -502 17 -238 ES panel 1:A
18 -498 18 -233 ES panel 2:A 11 12
13 -499 13 -234 ES panel 2:A
14 14 -231 ES panel 2:B
11 11 -232 ES panel 2:B
12 12 -235 ES panel 1:B
15 15 -236 ES panel 1:B
16 16
1 1
-S22
2 2 64 63 X1 X2
2 2
14 13
-X10 1 1 -X10 53 54
-XS4
1 BN/RD 0V 1 -206 0V 1
2 BN/OG EN1 2 -207 22 21 -214 EN 1_1 2
3 BN/YE EN2 3 -208 42 41 -215 EN 1_2 7
4 -496 4 -209 -216 ES FPU 1:A 17
5 -500 5 -210 -217 ES FPU 1:B 3
6 -495 6 -211 -218 ES FPU 2:A 4 FPU
7 -497 7 -212 -219 ES FPU 2:B 5
9 9 0V 11
EN2 8
12
MAIN /50.6 / TD+ AWG24 TD+ -X2 TD+
A31-A8 /50.6 / RD+ RD+ 2 RD+ 14

/50.6 / RD- RD- 3 RD- 15
6 16

Next 45
Prepared by, date: Approved by, date: OPTION : HOT PLUG 3HAC024480-004 03 Total 153
1 2 3 4 5 6 7 8
CONTROL
MODULE
-A21 +EXT-A21
-X9 -X9 -S21.1.X1
8 8 -226 AWG20 -244 EXT.MAN2 3
7 7 -225 AWG20 -243 EXT MAN FS2 2
6 6 -223 AWG20 -241 EXT.AUTO1 1
4 4 -222 AWG20 -240 EXT.MAN1 7
3 3 -221 AWG20 -239 EXT MAN FS1 6
2 2 5
3-MODE SELECTOR
-S21.1
6 12 10 2 4 8 18 22 24 14 16 20 OPTION
5 1 17 13

1 1 -224 AWG20 -246 EXT.COMMON2 8
5 5 4
MOTOR ON PB
-S21.2
-229 AWG20 14 13
10 10
-230
AWG20 X2 X1
19 19 -228 AWG20
9 9
EMERGENCY PB
-S21.3
-501 -237 ES panel 1:A 21 22
17 -502 17 -238 ES panel 1:A
18 -498 18 -233 ES panel 2:A 11 12
13 -499 13 -234 ES panel 2:A
14 14 -231 ES panel 2:B
11 11 -232 ES panel 2:B
12 12 -235 ES panel 1:B
15 15 -236 ES panel 1:B
16 16
1 1
2 2
2 2
-X10 1 1 -X10 -XS4

BN/BK 24V TPU -205 24V TPU_POWER
1 BN/RD 0V 1 -206 0V 1
2 BN/OG EN1_1 2 -207 EN 1_1 2
3 BN/YE EN1_2 3 -208 EN 1_2 7
4 -496 4 -209 ES TP 1:A 17
5 -500 5 -210 ES TP 1:B 3
6 -495 6 -211 ES TP 2:A 4
7 -497 7 -212 ES TP 2:B 5
8 BN/GN TPU_START 8 -213 TPU_START 6 FPU
9 9 0V 11
EN2 8
12
TD+
MAIN /50.6 / TD+ AWG24 TD+ -X2 TD- 13
COMPUTER /50.6 / TD- TD- 1 RD+ 14
A31-A8 /50.6 / RD+ RD+ 2 RD- 15

/50.6 / RD- RD- 3 16
6

Next 46
1 2 3 4 5 6 7 8
CONTROL
MODULE
-A21 +EXT-A21
-X9 -X9 -S21.1.X1
8 8 -226 AWG20 -244 EXT.MAN2 3
7 7 -225 AWG20 -243 EXT MAN FS2 2
6 6 -223 AWG20 -241 EXT.AUTO1 1
4 4 -222 AWG20 -240 EXT.MAN1 7
3 3 -221 AWG20 -239 EXT MAN FS1 6
2 2 5
3-MODE SELECTOR
-S21.1
6 12 10 2 4 8 18 22 24 14 16 20 OPTION
5 1 17 13

1 1 -224 AWG20 -246 EXT.COMMON2 8
5 5 4
MOTOR ON PB
-S21.2
-229 AWG20 14 13
10 10
-230
AWG20 X2 X1
19 19 -228 AWG20
9 9
EMERGENCY PB
-S21.3
-501 -237 ES panel 1:A 21 22
17 -502 17 -238 ES panel 1:A
18 -498 18 -233 ES panel 2:A 11 12
13 -499 13 -234 ES panel 2:A
14 14 -231 ES panel 2:B
11 11 -232 ES panel 2:B
12 12 -235 ES panel 1:B
15 15 -236 ES panel 1:B
16 16
1 1
-S22
2 2 64 63 X1 X2
2 2
14 13
-X10 1 1 -X10 53 54
-XS4
BN/BK 24V TPU -205 24V TPU_POWER
1 BN/RD 0V 1 -206 0V 1
2 BN/OG EN1_1 2 -207 22 21 -214 EN 1_1 2
3 BN/YE EN1_2 3 -208 42 41 -215 EN 1_2 7
4 -496 4 -209 -216 ES TP 1:A 17
5 -500 5 -210 -217 ES TP 1:B 3
6 -495 6 -211 -218 ES TP 2:A 4
7 -497 7 -212 -219 ES TP 2:B 5
8 BN/GN TPU_START 8 -213 TPU_START 6 FPU
9 9 0V 11
EN2 8
12
TD+
MAIN /50.6 / TD+ AWG24 TD+ -X2 TD- 13
COMPUTER /50.6 / TD- TD- 1 RD+ 14
A31-A8 /50.6 / RD+ RD+ 2 RD- 15

/50.6 / RD- RD- 3 16
6

Next 47
Prepared by, date: Approved by, date: OPTION : HOT PLUG 3HAC024480-004 03 Total 153
1 2 3 4 5 6 7 8
OPTION : FPU-PLUG
1) When external control panel connected to page 43 and 45
RunCh1
-XP4
3
RunCh0V
5
4
FLEXPENDANT
FLEXPENDANT -FPU1
1)
EMERGENCY-STOP
-XS4
-K1
/38.7 / ES FPU 1:A
3
/38.7 / ES FPU 2:A
5
/38.7 / ES FPU 2:B
6
/38.7 / ES FPU 1:B
4
PANEL -DP1 EN-DEVICE
/39.7 / 24V FPU POWER 2 1 1
BOARD -K2
A21-X10
12
-DP2
/39.7 / 0V PANELB 2 1 2
8
/39.7 / EN1_1
7
/39.7 / EN1_2
17
/39.7 / FPU START

11
/50.6 / TD+ AWG24

13
-ETH_FPU
MAIN /50.6 / TD-
COMPUTER 14
A31-A8 /50.6 / RD+

15
/50.6 / RD-
16

FPU, FLEXPENDANT Approved
Next 48
1 2 3 4 5 6 7 8
-S22
64 63 X1 X2
OPTION: FPU-PLUG
RunCh1
-XP4
3
RunCh0V
14 13 5
53 54 6
FLEXPENDANT
4
-FPU1
FLEXPENDANT
EMERGENCY-STOP
-XS4
-K1
/38.7 / ES FPU 1:A -216 BU
3
/38.7 / ES FPU 2:A -218 BU
5
/38.7 / ES FPU 2:B -219 BU
6
/38.7 / ES FPU 1:B -217 BU
4
PANEL -DP1 EN-DEVICE
/39.7 / 24V FPU POWER 2 1 1
BOARD -K2
A21-X10
12
-DP2
/39.7 / 0V PANELB 2 1 2
8
/39.7 / EN1_1 22 21 -214 BU
7
/39.7 / EN1_2 42 41 -215 BU
17
/39.7 / FPU START

11
/50.6 / TD+ AWG24

MAIN 13
-ETH_FPU
COMPUTER /50.6 / TD-
14
A31-A8
/50.6 / RD+
15
/50.6 / RD-
16

OPTION: HOT PLUG
Next 49
1 2 3 4 5 6 7 8
PANEL BOARD SEE PAGE 38 PANEL BOARD SEE PAGE 40;39

-A21 -A21
-X1 -XS/XP3 -X5 -XS/XP3

ES1 bottom -260 OG AWG20 BU 24V PANEL -272 AWG20 BU AWG20 BU
-X2 7 A1 12 C1
ES2 bottom -261 OG AWG20 BU AS1+ -273 AWG20 BU
7 B1 11 C2
24V PANEL -262 AWG20 BU AS1- -274 AWG20 BU AWG20 BU
8 B2 9 C3
0V -263 AWG20 BU 0V -275 AWG20 BU
8 A2 7 C4
24V PANEL -264 AWG20 BU AWG20 BU AWG20 BU
4 A3 C5
Run CH1 top GS1+ -276 AWG20 BU
5 10 C6
Run CH2 top GS1- -277 AWG20 BU AWG20 BU
5 8 C7
0V -265 AWG20 BU AWG20 BU
4 B3 C8
ES2 top -266 OG 24V PANEL -278 AWG20 BU AWG20 BU
3 B4 6 D1
ES1 top -267 AS2+ -279

OG AWG20 BU
3 A4 5 D2
Sep ES1:A -268 OG AWG20 BU AS2- -280 AWG20 BU AWG20 BU
9 A5 3 D3
Sep ES2:A -269 OG AWG20 BU 0V -281 AWG20 BU
9 B5 1 D4
Sep ES2:B -270 OG AWG20 BU
10 B6 D5
Sep ES1:B -271 OG GS2+ -282 AWG20 BU
10 A6 4 D6
ES1 OUT A -284 OG GS2- -283 AWG20 BU AWG20 BU
1 A7 2 D7
ES1 OUT B -285 OG
2 A8 D8
ES2 OUT A -286 OG
1 B7
-287 -X6
ES2 OUT B OG
2 B8 0V -289 AWG20 BU AWG20 BU
1 A10
SS1- -291 AWG20 BU
2 B10
SS2- -293 AWG20 BU
3 C10
SS1+ -290 AWG20 BU
4 B9
SS2+ -292 AWG20 BU
5 C9
24V PANEL -288 AWG20 BU AWG20 BU
6 A9
10

OPTION: EXTERNAL CONNECTION Approved
SYSTEM SIGNALS
Next 50
1 2 3 4 5 6 7 8
CONTROL
MODULE
MAIN COMPUTER DSQC639
-A31
-A9
TX+ / /90.2 /92.2 /92.1.2 DRIVE
1 TX- / /90.2 /92.2 /92.1.2 MODULE
2 RX+ / /90.2 /92.2 /92.1.2 AXIS
AXC1 3
-X1 COMPUTER
ETH_DRIVE 4
/33.3 /87.5 / 24V PC;1 5 RX- / /90.2 /92.2 /92.1.2
1 6
PROCESS /33.3 /87.5 / 24V PC;2 7
POWER SUPPLY 4 8
/33.3 /87.5 / 0V PC;1
2
/33.3 /87.6 / 0V PC;2
3
-X23
-A7
PWR LED (GREEN)
TX+ AWG24 WHOG
1 TX- OG 1 SERVICE
2 RX+ WHGN 2 PORT
3 3
ETH_SERVICE 4
5 RX- GN
IDE LED (YELLOW)

6 6
7
8
STATUS LED (RED-GREEN)

_TX+ / /73.2 OPTION:
_TX- / /73.2 REMOTE
_RX+ / /73.2 SERVICE
_RX- / /73.2
-X8
AWG24
1
2 WHGN 24V_Sig.ref. / /38.7
3 BU RS485+ / /38.7
PANEL UNIT 4 WHBU RS485- / /38.7 PANEL BOARD
RS 485 5
6 WHBN 0V_Sig.ref. / /38.7
7
CHASSIS BLOWER 8
-E22
- -A8
M TD+ / /47.2 /48.2 /43.2 /44.2 /45.2 /46.2

3
-J21 TD- / /47.2 /48.2 /43.2 /44.2 /45.2 /46.2
+
GND AWG24 BK ETH_FPU 6 FLEXPENDANT

1 +24V RD 4
2 FAN_TACH YE 5 RD+ / /47.2 /48.2 /43.2 /44.2 /45.2 /46.2
3 1
RD- / /47.2 /48.2 /43.2 /44.2 /45.2 /46.2
2
7
8

MAIN COMPUTER DSQC 639 Approved
Sublocation: +
Next 51
1 2 3 4 5 6 7 8
-A31 MAIN COMPUTER DSQC639

CONTROL
MODULE
-LAN1 -XP28
OPTION: TX+
232/422/485 SERIE CONVERTER 1 TX- 1
-A39 2 2
OPTION : EXTERN LAN
RX+
3 RX- 3
-X1 -X2 COM1
-J2 6 6
RX- A1 COM1_DCD
TX+ 1 1 A2 COM1_RXD
TX- 2 2 A3 COM1_TXD
3 3 A4 COM1_DTR
0V 4 4 A5 0V
5 5 A6 COM1_DSR
6 6 A7 COM1_RTS-N
OPT. EXTERNAL PWR 7 7 A8 COM1_CTS-N
RX+ 8 8 A9 COM1_RI
9 9
-X24
-USB1
AWG28 GN USB1 D+
3 AWG28 WH USB1 D- 3
2 AWG24 BK USB1_GND 2
USB
4 AWG24 RD USB1 +5V 4 CONTROL MODULE
1 1
MC CONSOLE
-J2
/73.2 / CON_DCD CONSOLE_DCD
OPTION: REMOTE SERVICE /73.2 / CON_RXD B1 CONSOLE_RXD
/73.2 / CON_TXD B2 CONSOLE_TXD
/73.2 / CON_DTR B3 CONSOLE_DTR
/73.2 / CON_GND B4 GND
-USB2
/73.2 / CON_DSR B5 CONSOLE_DSR AWG28 GN USB2 D+ / /33.7 /87.8 PROCESS
/73.2 / CON_RTS-N B6 CONSOLE_RTS-N 3 AWG28 WH USB2 D- / /33.7 /87.8 POWER SUPPLY
/73.2 / CON_CTS-N B7 CONSOLE_CTS-N 2 AWG24 BK USB2_GND / /33.7 /87.8
/73.2 / CON_RI B8 CONSOLE_RI 4 AWG24 RD USB2 +5V / /33.6 /87.8
B9 1

Sublocation: +
Next 52
1 2 3 4 5 6 7 8
ETHERNET/IP Fieldbus adapter DSQC 669

-A38.1
-Z1
-X1
TX+ OPTION & HARNESS TO CUSTOMER I/O
TX- 1
2
RX+
3
CompactCom 4
RX- 5
6
7
8
PROFIBUS Fieldbus adapter DSQC 667

-A38.2
-Z1
-X1
SLAVE SHIELD OPTION & HARNESS TO CUSTOMER I/O
RXD/TXD-p 1
3
CONTROL-P
4
CompactCom GND
5
+5VDC 6
RXD/TXD-N 8
PROFINET IO Fieldbus adapter DSQC 688

-A38.3
-Z1
-X1
TX+ OPTION & HARNESS TO CUSTOMER I/O
TX- 1
2
RX+
3
CompactCom 4
RX- 5
6
7
8

FIELDBUS ADAPTER: Approved
Sublocation: +
ETHERNET/IP, PROFIBUS and
Next 53
Prepared by, date: Approved by, date: PROFINET IO 3HAC024480-004 03 Total 153
1 2 3 4 5 6 7 8
COMPUTER UNIT AC/BD

-A3
COMPUTER UNIT DSQC623
COMPUTER POWER SUPPLY -A31
-G31
-P1 -J4H1
-X1 -X1 OR +3.3V
24V OR +3.3V 1
1 V+ BK GND 2
PROCESS 24V RD +5V 3
POWER SUPPLY 4 BK GND 4
-G2.X3 0V RD +5V 5
2 BK GND 6
0V -PSU-X1 7
3 V- GY PWR_OK
-PSU-X2 1 8
VT +5VSB
-P1 1 9
YE +12V
OR +3.3V 10
BU -12V 11
-PSU-X2 12
MOTHER BK GND
BOARD
2 GN PS_ON 13
POWER -P1 3 14
BK GND
BK GND 15
BK GND 16
17
RD +5V 18
RD +5V 19
20
SOLID STATE DRIVE

-D32 -J6H1
40
-X1 -X2
ATA/IDE
-IDEpwr1 1
GND 2
+5V 3
4
SOLID STATE DRIVE

REMARK:
-D31
P1 & J6H1 CONNECTS
-X2 40
TO EITHER D32 OR D31
-X1
DEPENDING OF CHOSED OPTION.
1
1
GND 2
+5V 3
4

MAIN COMPUTER AC/BD Approved
Next 54
1 2 3 4 5 6 7 8
COMPUTER UNIT AC/BD

-A3
COMPUTER POWER SUPPLY

-G31
P1
BK GND
YE +12V
CHASSIS BLOWER
-E22
M
AWG 24
COMPUTER UNIT DSQC623 -C2
+
-A31 BK GND BK
-J9H1 YE +12V 1 RD
2
1
2 WH FAN2_TACH
3
CHASSIS BLOWER
-E23
-J9H2
1 -
2
3
M
AWG 24
-C1
+
BK GND BK
YE +12V 1 RD
2
WH FAN1_TACH

Next 55
1 2 3 4 5 6 7 8
COMPUTER UNIT AC/BD

CONTROL
-A3
MODULE
OPTION:
-A31 COMPUTER UNIT DSQC623
232/422/485 SERIE CONVERTER
-A39 PWR LED (GREEN)
-J9H3
A K
-X1 -X2 -J2 COM1 2
RX- COM1_DCD
TX+ 1 1 A1 COM1_RXD 4
IDE LED (YELLOW)
TX- 2 2 A2 COM1_TXD
3 3 A3 COM1_DTR A K
0V 4 4 A4 0V 1
5 5 A5 COM1_DSR
6 6 A6 COM1_RTS-N 3
RX+ 8 8 A8 COM1_RI
9 9 A9 -LAN1
TX+
1 TX-
2 RX+
3 RX-
6
-X24
-USB1
-J2 MC CONSOLE AWG28 GN USB1 D+
B1 CONSOLE_DCD 3 AWG28 WH USB1 D- 3
B2 USB
CONSOLE_RXD CONTROL MODULE
B3 4 AWG24 RD USB1 +5V 4
CONSOLE_TXD
B4 1 1
CONSOLE_DTR
B5
GND
B6
CONSOLE_DSR
B7
CONSOLE_RTS-N -USB2
B8 AWG28 GN USB2 D+
CONSOLE_CTS-N
B9 CONSOLE_RI 3 AWG28 WH USB2 D- PROCESS
2 AWG24 BK USB2_GND POWER SUPPLY
4 AWG24 RD USB2 +5V
-G2.X5
1
-USB3
3
2
4
1
-USB4
3
2
4
1

Next 56
1 2 3 4 5 6 7 8
ROBOT COMMUNICATION CARD DSQC602

-A32
-X8
1
2 WHGN 24V_Sign.ref
3 BU RS485+
RS 485 4 WHBU RS485- PANEL BOARD
5 -A21.X11
6 WHBN 0V_Sign.ref
7
8
-A8
OG TD+
3
WHOG TD- FLEXPENDANT
ETH_FPU 6 -XS4
4
5 GN RD+
1
-X1
WHGN RD-
2
7
8
CONTROL
MODULE
-A9
PCI BUS TX+
1 TX-
2 RX+
3 RX- DRIVE MODULE
ETH_DRIVE 6 AXIS COMPUTER
4
5
7
8
-A7 -X23
TX+ 1
1 TX- 2 SERVICE
2 RX+ 3 PORT
ETH_SERVICE 3
4
5 RX- 6
6
7
8

ROBOT COMM. CARD DSQC 602
Next 57
1 2 3 4 5 6 7 8
PROFIBUS DP M/S
-A33
Customer
Connection
-A33.1-Z1
-A33-X2
SHIELD
RXD/TXD-P 1 1B
SLAVE CONTROL-P 3
PCI BUS GND 4
OPTION & HARNESS TO CUSTOMER I/O

+5VDC
5
RXD/TXD-N 6 1A
8
-A33-X3
SHIELD
RXD/TXD-P 1 1B
MASTER CONTROL-P 3
GND 4
+5VDC 5
RXD/TXD-N 6 1A
8

PROFIBUS DP M/S Approved
Sublocation: +
Next 57.1
1 2 3 4 5 6 7 8
Customer
Connection
PROFINET DSQC678
-A33.1
-X1
TX+
1 TX-
2 RX+
3
4
5 RX-
6
7
8
-X2
TX+
1 TX-

-Z1 2 RX+
3
4
RX-
5
6
7
PCI BUS 8
-X3
TX+
1 TX-
2 RX+
3
4
5 RX-
6
7
8
-LAN1
TX+
1 TX-
2 RX+
3
4
5 RX-
6
7
8

PROFINET Approved
Sublocation: +
Next 58
1 2 3 4 5 6 7 8
INTERBUS M/S (OPTICAL FIBRE) INTERBUS M/S (COPPER WIRE)

-A37 -A37
-A37.1
-A37.1 1)
-X4
24V
INTERBUS SLAVEPART 24V+
INTERBUS SLAVEPART
0V
-X2 1) 0V
-Z1 24V -Z1

24V+
REMOTE IN -X5
0V DO
0V 1 DON
6 DI
2 DIN
-FO1
PCI BUS LW/BK PCI BUS 7 GNDISI
BK1(IN) 3
LW/OG
GY (OUT)

-FO2 -X1

REMOTE OUT
LW/BK DO
BK1(IN) 1 DON
LW/OG DI
6
GY (OUT) 2 DIN
7 GRND
3 VCCISO
5 RBST
9
-A37.2
-FO3
LW/BK
INTERBUS MASTERPART REMOTE
BK (IN)
LW/OG
GY (OUT)
-A37.2
REMOTE -X2
DO
INTERBUS MASTERPART 1 DON
6 DI
2 DIN
-X1 7 GNDIM
TXD 3 GRND
1 RXD 4 VCCIM
2 GND 5 VCC
4 RTS 8
5 CTS
6
RS232 -X3
TXD
1 RXD
2 GND
4 RTS
5 CTS
6
1) IT IS IMPORTANT THAT 24 DC EXT SUPPLY ALWAYS IS AVAILABLE

OTHERWISE THE INTERBUS CAN NOT WORK
IF THE CONTROLLER IS TURNED OFF.

INTERBUS M/S Approved
Sublocation: +
Next 59
1 2 3 4 5 6 7 8
CONTROL
DEVICE NET ADAPTER
MODULE
-A35
-CHA-J1 -A35-X1 -XS17

BK
P1 1 1 3
BU
2 2 5
SC OPTION
3 3 1
WH
4 4 4
PCI BUS RD
5 5 2
V- / /60.2
CAN_L / /60.2
DRAIN / /60.2
CAN_H / /60.2
V+ / /60.2
ONLY FOR DUAL DEVNETCARD DSQC 659

-CHB-J2
2
CUSTOMER OPTION BUS
3

DEVICENET SINGLE/DUAL ADAPTER Approved
Sublocation: +
Next 60
1 2 3 4 5 6 7 8
-I/O1
/59.5 / V-
/59.5 / CAN_L 1
/59.5 / CAN_H 2
/59.5 / V+ 4
/59.5 / DRAIN 5 BK V- / /63.1
3 BU CAN_L / /63.1
WH CAN_H / /63.1 Digital I/O unit
RD V+ / /63.1
-I/O2
SC DRAIN / /63.1
1
2 BK V- / /66.2
4 BU CAN_L / /66.2
5 WH CAN_H / /66.2 Relay I/O unit
3 RD V+ / /66.2
SC DRAIN / /66.2
-I/O3 ONLY FOR DUAL CONTROL

BK V- / /68.1
1 BU CAN_L / /68.1
2 WH CAN_H / /68.1 Analogue I/O unit
4 RD V+ / /68.1
5 SC DRAIN / /68.1
3
BK V- / /69.1 OPTION: HARNESS
BU CAN_L / /69.1 TO CUSTOMER I/O
-I/O4 ONLY FOR DUAL CONTROL
WH CAN_H / /69.1 Remote I/O unit
1 RD V+ / /69.1
2 SC DRAIN / /69.1
4
5 BK V- / /70.2
3 BU CAN_L / /70.2
WH CAN_H / /70.2 Interbus slave
RD V+ / /70.2
SC DRAIN / /70.2
BK V- / /71.1
-A35-X2 BU CAN_L / /71.1
/35.6 /37.4 /34.2 /36.5 / 0Vdevicenet;1 WH CAN_H / /71.1 Profibus DP slave
1 RD V+ / /71.1
SC DRAIN / /71.1
2 120 OHM
BK V- / /72.1
4 BU CAN_L / /72.1
/35.6 /37.3 /34.2 /36.5 / +24Vdevicenet;1 WH CAN_H / /72.1 Encoder unit
5 RD V+ / /72.1
SC DRAIN / /72.1
3

DEVICENET ADAPTER Approved
Sublocation: +
Next 61
1 2 3 4 5 6 7 8
DUAL RS232 CARD

-A34
-X1
1 COM2_RXD
2 COM2_TXD
COM2_DTR
3
COM2 4 0V
RS232 5 COM2_DSR
6 COM2_RTS-N
7 COM2_CTS-N
8
X5 9
-X2
1 COM3_RXD
PCI BUS 2 COM3_TXD
3 COM3_DTR
COM3 4 0V
RS232 5 COM3_DSR
6 COM3_RTS-N
7 COM3_CTS-N
8
9

DUAL RS232 CARD Approved
Sublocation: +
Next 62
1 2 3 4 5 6 7 8
ETHERNET CARD
-A36
-A1
TX+
1 TX-
2 RX+
3 DRIVE MODULE 2 (OPTION)
4
5 RX-
X1 6
7
8
-A2
TX+
1 TX-
PCI BUS 2 RX+
4
5 RX-
6
7
8
-A3
TX+
1 TX-
2 RX+
4
5 RX-
6
7
8

ETHERNET CARD Approved
Sublocation: +
Next 63
1 2 3 4 5 6 7 8
TO NEXT
I/O UNIT
2)
120 ohm
3) 2 1
/35.6 /37.4 /34.3 /36.6 / +24Vdevicenet;2 DIG. PART OF COMBI I/O AND DIG. I/O UNIT DSQC 651& 652
-I/Ox
/35.6 /37.4 /34.3 /36.6 / 0Vdevicenet;2
XTXX.X3
-X3
INPUT CH.1
1 2
2 3
3 4
-X5
/60.5 / V- 4 5
/60.5 / CAN_L 1 5 6
/60.5 / CAN_H 2 6 7
/60.5 / V+ 8
4 7
5 8 0V
/60.5 / DRAIN 9
0V 3 10
OR PREVIOUS NA0 6
I/O UNIT NA1 7

1) NA2 8 0V
NA3 9 4)
NA4 10 XTXX.X4
NA5 11
-X4
12 INPUT CH.9
1 10
2 11
3 12
4 13
5 14
6 15
1) JUMPERS PLACED ACCORDING TO 7 16
THE ACTUAL NODE ADDRESS. 8 0V
9
10
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.
4) ONLY FOR DIGITAL I/O DSQC 652.

DIGITAL PART OF COMBI I/O AND Approved
Sublocation: +
DIGITAL I/O UNIT
Next 64
1 2 3 4 5 6 7 8
DIGITAL I/O UNIT DSQC 652

-I/Ox
OUTPUT CH 1-8
XTXX.X1
<1 -X1
OUTPUT CH.1
1 2
2 3
3 4
4 5
5 6
6 7
7 8
8 0V
0V 9 24V DC
10
OUTPUT CH 9-16
XTXX.X2
<1 -X2
OUTPUT CH.9
0V
1 10
2 11
3 12
4 13
5 14
6 15
7 16
8 0V
9 24V DC
10

DIGITAL I/O UNIT Approved
Sublocation: +
Next 65
1 2 3 4 5 6 7 8
-I/OxCOMBI I/O UNIT DSQC 651
OUTPUT CH 1-8
XTXX.X1
<1 -X1
OUTPUT CH.1
1 2
2 3
3 4
4 5
5 6
6 7
7 8
8 0V
0V 9 24V DC
10
-X6
INPUT CH.1
CPU INPUT CH.2 1
2
0V
3
DAC
OUTPUT CH.1
5
REF 0VA
4
OUTPUT CH.2
6
+15V
DC
0VA
DC
-15V

COMBI I/O UNIT Approved
Next 66
1 2 3 4 5 6 7 8
TO NEXT
I/O UNIT
2)
120 ohm
2 1
3) DIG. PART OF RELAY I/O UNIT DSQC 653

-I/Ox
/35.6 /37.4 /34.3 /36.6 / +24Vdevicenet;3
XTXX.X3
/35.6 /37.4 /34.3 /36.6 / 0Vdevicenet;3
-X3
INPUT CH.1
1 2
2 3
-X5 3 4
/60.5 / V- 4 5
/60.5 / CAN_L 1 5 6
/60.5 / CAN_H 2 6 7
/60.5 / V+ 4 7 8
0V
5 8
/60.5 / DRAIN 9
0V 3
OR PREVIOUS NA0 6
I/O UNIT NA1 7 0V

1) NA2 8
NA3 9
NA4 10
NA5 11
12
1) JUMPERS PLACED ACCORDING TO

THE ACTUAL NODE ADDRESS.


CAN-BUS CIRCUIT.

RELAY I/O UNIT Approved
Next 67
1 2 3 4 5 6 7 8
RELAY I/O UNIT DSQC 653

-RELAY I/O
XTXX.X1
-X1
OUT CH.1A
1
OUT CH.1B
2
OUT CH.2A
3
OUT CH.2B
4
OUT CH.3A
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
OUT CH.7B
14
OUT CH.8A
15
OUT CH.8B
16

Next 68
1 2 3 4 5 6 7 8
TO NEXT
I/O UNIT
2) ANALOGUE I/O UNIT

-I/Ox
120 ohm
2 1
3)
-X7
ANOUT_1
/35.7 /37.4 /34.3 /36.6 / +24Vdevicenet;4 1 ANOUT_2
2 ANOUT_3
ADC MUX
/35.7 /37.4 /34.3 /36.6 / 0Vdevicenet;4 3 ANOUT_4
4 0V
19 0V
0V 20 0V
21 0V
-X5
/60.5 / V- 22
/60.5 / CAN_L 1
/60.5 / CAN_H
2
/60.5 / V+ 4
5
/60.5 / DRAIN
0V 3 REF
DAC
OR PREVIOUS NA0 6
-X8
I/O UNIT NA1 7 ANIN_1
1) NA2 8 1 ANIN_2
NA3 9 2 ANIN_3
NA4 10 3 ANIN_4
NA5 11 4
12 24V
17
18
19
20
21
0V 22
1) JUMPERS PLACED ACCORDING TO 23

25 0V
26 0V
27 0V
BE CONNECTED IN THE FIRST AND THE 28

CAN-BUS CIRCUIT.

ANALOGUE I/O UNIT Approved
Next 69
1 2 3 4 5 6 7 8
TO NEXT
I/O UNIT
2)
120 ohm
2 1
3)
/35.7 /37.5 /34.3 /36.7 / +24Vdevicenet;5
/35.7 /37.5 /34.4 /36.7 / 0Vdevicenet;5

REMOTE I/O UNIT
-I/Ox
-X5
/60.5 / V-
/60.5 / CAN_L 1 NAC
/60.5 / CAN_H 2 -X8
/60.5 / V+ LINE 1 (BLUE)

4
5 1 REMOTE I/O IN
/60.5 / DRAIN
0V 3 LINE 2 (CLEAR)
OR PREVIOUS NA0 6 1 2
I/O UNIT NA1 7 -X9

1) NA2 8 (BLUE)
NA3 9 1 REMOTE I/O OUT
NA4 10
NA5 11 (CLEAR)
12 2


4
CAN-BUS CIRCUIT.

REMOTE I/O UNIT Approved
Next 70
1 2 3 4 5 6 7 8
TO NEXT
I/O UNIT
2)
120 ohm
2 1
3)
/35.7 /37.5 /34.4 /36.7 / +24Vdevicenet;6 INTERBUS SLAVE

-I/Ox
/35.7 /37.5 /34.4 /36.7 / 0Vdevicenet;6
-X5 -X21
/60.5 / V-
/60.5 / CAN_L 1 TPDO2
/60.5 / CAN_H 2 1 TPDI2
/60.5 / V+
4 2 GND
5 3 +5VDC IB-S OUT
/60.5 / DRAIN 5 TPDO2-N
0V 3 6 TPDI2-N
OR PREVIOUS NA0 6 7 RBST
I/O UNIT NA1 7 9
1) NA2 8
NA3 9
NA4 10
NA5 11
12
-X20
TPDO1
1 TPDI1
2 GND IB-S IN
3 TPDO1-N
6 TPDI1-N
-X3
GND 7
4) 24V DC EXT. SUPPLY 1
+24VDC 3
5


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.

INTERBUS SLAVE Approved
Next 71
1 2 3 4 5 6 7 8
TO NEXT
I/O UNIT
2)
120 ohm
2 1
PROFIBUS DP SLAVE
-I/Ox
3)
/35.8 /37.5 /34.4 /36.7 / +24Vdevicenet;7

Customer
/35.8 /37.5 /34.4 /36.7 / 0Vdevicenet;7 Connection
-X5
/60.5 / V-
-X20
/60.5 / CAN_L 1 SHIELD
/60.5 / CAN_H 2 1
/60.5 / V+
4 RXD/TXD-P
5 3 CONTROL-P
/60.5 / DRAIN 4 GND
0V 3 5 +5VDC
OR PREVIOUS NA0 6 6 RXD/TXD-N
I/O UNIT NA1 7 8
1) NA2 8
NA3 9
NA4 10
NA5 11
12
-X3
0V DC
External supply GND 1
+24VDC 3
5



CAN-BUS CIRCUIT.

PROFIBUS DP SLAVE Approved
Next 72
1 2 3 4 5 6 7 8
TO NEXT
I/O UNIT
2)
120 ohm
2 1
ENCODER UNIT
-I/Ox
3)
/35.8 /37.6 /34.4 /36.8 / +24Vdevicenet;8 Encoder

Connection
/35.8 /37.6 /34.4 /36.8 / 0Vdevicenet;8
-X20
24 VDC
1
-X5
/60.5 / V- 0V
/60.5 / CAN_L 1 2
/60.5 / CAN_H 2 ENC +24V
/60.5 / V+
4 3
5 ENC 0V
/60.5 / DRAIN 4 Encoder
0V 3 2 1 ENC_A
OR PREVIOUS NA0 6 5
NA1 7 A
I/O UNIT ENC_B
1) NA2 8
1
6
NA3 9 +24V
NA4 10 7
NA5 11 0V Synch switch
12 2 1 8
DIGIN
A 9
2 1
A
1

CAN-BUS CIRCUIT.

ENCODER UNIT Approved
Next 73
1 2 3 4 5 6 7 8
OPTION: REMOTE SERVICE BOX

-A61
(( ))
-X1
/35.8 /36.8 /37.6 /34.5 / 0V ReS 746
-X2 -X18
1
/35.8 /36.8 /37.6 /34.5 / 24V Res 745
2
AWG24 AWG24
-X23
-X10 -X11
/50.7 / _TX+ WHOG WHOG
1 1 1
/50.7 / _TX- OG OG
2 2 2
/50.7 / _RX+ WHGN WHGN
3 3 3
4 4
5 5
/50.7 / _RX- GN GN
6 6 6
7 7
8 8
-X15
/51.3 / CON_RTS-N BU
1
/51.3 / CON_TXD RD
2
/51.3 / CON_RXD BN
3
/51.3 / CON_DSR GN
4
/51.3 / CON_GND YE
5
/51.3 / CON_DTR OG
6
/51.3 / CON_DCD BK
7
/51.3 / CON_CTS-N
8
/51.3 / CON_RI VO
9

REMOTE SERVICE Approved
Next 80
1 2 3 4 5 6 7 8
Drive module + DM
CAB = Common cabinet

Plant =
CAB.DC = Dual cabinet

CAB.SC = Single cabinet
Location + DM
Sublocation = SLO.1 or SLO.2 etc. shows that the sheet is a variant of the DM

DRIVE MODULE Approved
Sublocation: +
Next 82
1 2 3 4 5 6 7 8
-XP0 1 2 3
AWG10 BK
AWG10 BK
AWG10 BK
AWG10 GNYE
-101
-102
-103
1 3 5
-Q1
2 4 6
-109 AWG10 BK
-108 AWG10 BK
-107 AWG10 BK OPTION:

CIRCUIT BRAKER
101
102
103
-F6 1 3 5 OPTION :
FLANGE DISCONNECT
-Q1 1 2 3
2 4 6
T1 T2 T3
110
111
112
-106 AWG10 BK
-105 AWG10 BK
-104 AWG10 BK OPTION:

1 3 5
MAINS LINE FILTER
-Z1
2 4 6
AWG10 BK
AWG10 BK
AWG10 BK
-110
-111
-112
/83.3 / L1
/83.3 / L2
/83.4 / L3
TRANSFORMER UNIT

MAINS CONNECTION Approved
Sublocation: +
Next 83
AWG10 GNYE
-T1
/87.8 / 230V AC1_SC;1
Latest revision:
1
/86.7 / 230V AC1_SC;2
Prepared by, date:

/87.8 / 230V AC2_SC;1
SINGLE
CABINET
1) T1.1 6kVA
2) T1.2 13kVA
/86.7 / 230V AC2_SC;2
POWER SUPPLY
200V
TRANSFORMER UNIT
220V
-X2
/85.4 / 230V AC1_DC 230V
400V
DUAL
CABINET
/85.4 / 230V AC2_DC 230V 440V
2
-X1
L1-L2-L3 = 480VAC if IRB660, 6600-7600
POWER SUPPLY
1) 480V
262/480VAC
Approved by, date:

/89.8 / T1_L1 500V
L1-L2-L3 = 262VAC if IRB140-340, 1400-4400, 6400R
262/480VAC 600V
/89.8 / T1_L2
1), 2)
UNITS
262/480VAC
/89.8 / T1_L3
CONTACTOR
REAKTOR UNIT
-Z2
200V
-X2
-X1
-L1
220V
F2
F1
3
L1IN
F4
F3
L2IN
400V
-X10
-113 AWG10 BK L1 / /82.4

1
F6
F5
440V
L3IN
L1UT L2UT L3UT
ONLY FOR
AWG10 BK
IRB 6600-7600
-114 L2 / /82.4
2
230VAC 1) 480V
/84.3 / T1_230V -115 AWG10 BK L3 / /82.4
1
3
115VAC 500V
MAINS CONNECTION
/84.3 / T1_115V
2
600V
OUTLET
N
SERVICE
/84.3 / T1_N
3
4
200V
220V
400V
440V
Lab/Office:
1) 480V
500V
600V
5
/87.8 / 230V AC1_SC;1

AWG10 GNYE
-T1
/86.7 / 230V AC1_SC;2
TRANSFORMER UNIT
/87.8 / 230V AC2_SC;1
SINGLE
CABINET
/86.7 / 230V AC2_SC;2

POWER SUPPLY
6
USED FOR:
T1.3 2,5kVA
IRB7600 480V
-X2
TRANSFORMER UNIT
-X1
/85.4 / 230V AC1_DC 230VAC IN

IRB660, 6600 400-480V
230V
DIRECT POWER SUPPLY
230VAC
DUAL
/85.4 / 230V AC2_DC

CABINET
230VAC 400V
1
POWER SUPPLY
440V
115VAC
2
480V
N
Status:
/84.3 / T1_230V
3
/84.3 / T1_115V
7
/84.3 / T1_N
Document no.
OUTLET
SERVICE
Approved
2008-07-17
-Z2
REAKTOR UNIT
-X2
-X1
-L1
/89.8 / T1_L1 113

Plant:
F2
F1
L1IN
Location:
3HAC024480-004
/89.8 / T1_L2 114

F4
F3
UNITS
L2IN
Sublocation: +
/89.8 / T1_L3 115

CONTACTOR
F6
F5
+ DM
8
L3IN
L1UT L2UT L3UT
03
= CAB
Rev. Ind
Next 84
Page 83
Total 153
1 2 3 4 5 6 7 8
T1_230V / /83.4 /83.7
T1_115V / /83.4 /83.7
T1_N / /83.4 /83.7

OPTION:
SERVICE OUTLET -184 4 3
SINGLE/DUAL CONTROL AWG16

CIRCUIT BREAKER
1 3
-F5
2 4
AWG16 BK
-183
-F4 1 3
EARTH FAULT
BREAKER
2 4
-185 1 2
-186 AWG16 GNYE AWG18
-X22
GND 1 2

OPTION : SERVICE OUTLET Approved
Sublocation: +
Next 85
Latest revision:
1
Prepared by, date:

-G1
-X2
UNIT
/90.2 / +24V DRIVE BK
1
/90.2 / 0V DRIVE BN
AXIS COMP.
4
DRIVE POWER SUPPLY
/90.6 / 24V Drive sys RD
2
2
/90.6 / 0V Drive sys OG
DRIVE UNIT
5
MAIN SERVO
Approved by, date:

/88.2 / +24V DRIVE;1 -463 AWG18 BU
UNIT
/88.2 / 0V DRIVE;1 -464 AWG18 BU
CONTACTOR
3
-X3
/88.2 / +24V BRAKE;1 -465 AWG16 BU
1
/88.2 / +24V BRAKE;2 -466 AWG16 BU
UNIT
/88.2 / +24V COOL;1 -469 AWG16 BU
3
-F2
-467 AWG16 BU
CONTACTOR
/88.2 / 0V BRAKE;1
5
/88.2 / 0V BRAKE;2 -468 AWG16 BU
-X1
6
AWG16 GNYE
-470 AWG16 BU
4
/88.2 / 0V COOL;1
7
-152 AWG16 BK 23
1
1
2
/94.3 / +24V COOL;3 -510 AWG20 BU 0V

1/BK
-153 BK -156 23
AC
5
14
11
1_
3
BK
4
/94.3 / +24V COOL;2 -511 AWG20 BU 0V D

AC C
2_ //
83
/94.3 / 0V COOL;3 -512 AWG20 BU D .2
C
DRIVE UNIT
8
2/BK AWG16
/8
MAIN SERVO
// 3.
-513 AWG20 BU
83 6
Lab/Office:
/94.3 / 0V COOL;2 .2
/8
3.
6
5
-X4
/90.2 / 5V_OUT BK
1
UNIT
/90.2 / ACOK BN
2
/90.2 / BRAKEOK RD
AXIS COMP.
3
FOR DUAL CABINET

/90.2 / TEMPOK OG
4
-155
-154
6
-K41
A2
A1
AWG16 BK
AWG16 BK
POWER SUPPLY DSQC 626 AND 627

AWG16 GNYE

-141
-140
AWG20 BU
AWG20 BU
2
1
Status:
-K41.X1
2
1
7
Document no.
Approved
2008-07-17
GND_DM / /32.3
0V;1 / /41.7
230V AC2_DM / /32.3
230V AC1_DM / /32.3
Plant:
AC_ON1 / /41.7
Location:
3HAC024480-004
Sublocation: +
+ DM
8
03
A21.X7
= CAB.DC
MODULE
MODULE
CONTROL
CONTROL
PANEL BOARD
Next 86
Rev. Ind Page 85
Total 153
Latest revision:
1
Prepared by, date:

-G1
-X2
UNIT
/90.2 / +24V DRIVE BK
1
/90.2 / 0V DRIVE BN
AXIS COMP.
4
2
DRIVE POWER SUPPLY
DRIVE UNIT
5
MAIN SERVO
2
/88.2 / +24V DRIVE;1 -_463 AWG16 BU
UNIT
Approved by, date:

/88.2 / 0V DRIVE;1 -_464 AWG16 BU
CONTACTOR
-X3
/88.2 / +24V BRAKE;1 -_465 AWG16 BU
1
3
/88.2 / +24V BRAKE;2 -_466 AWG16 BU
2
/88.2 / +24V COOL;1 -_469 AWG16 BU
3
/88.2 / 0V BRAKE;1 -_467 AWG16 BU
UNIT
/88.2 / 0V BRAKE;2 -_468 AWG16 BU
6
-_470 AWG16 BU
CONTACTOR
/88.2 / 0V COOL;1
7
-PE1
/94.3 / +24V COOL;3 -_510 AWG20 BU

-X1
4
AWG16 GNYE
-511 AWG20
BU
4
/94.3 / +24V COOL;2

1
/94.3 / 0V COOL;3 -_512 AWG20 BU

8
5
BU
/94.3 / 0V COOL;2 -513 AWG20
DRIVE UNIT
MAIN SERVO
Lab/Office:
-153
-152
-X4
/90.2 / 5V_OUT BK
1
AWG16 BK
AWG16 BK
5
/90.2 / ACOK BN
2
UNIT
/90.2 / BRAKEOK RD
3
AXIS COMP.
/90.2 / TEMPOK OG
4
FOR SINGLE CABINET

6
-XT16
L1
/36.4 / 230V AC1;1 -181 AWG16 BK

L1
-F2
/36.2 / 230V AC1;2 -308 AWG16 BK

L1
/33.3 / 230V AC1;3 -177 AWG16 BK

L1
JUMPER
L1
Status:
23
7
L1
2
0V
1/BK
Document no.
Approved
AC
23
L2
1_
3
0V SC
2008-07-17
AC ;2
L2
2_ //
SC 83
2/BK AWG16
-182 AWG16 BK ;2 .1
/36.4 / 230V AC2;1 /8
L2
// 3.
83
.1 6
/36.2 / 230V AC2;2 -309 AWG16 BK
Plant:
/8
L2
3.
6
JUMPER
Location:
3HAC024480-004
/33.3 / 230V AC2;3 -178 AWG16 BK

L2
Sublocation: +
L2
+ DM
8
03
= CAB.SC
Next 87
Rev. Ind Page 86
Total 153
-G2
/90.2 / +24V DRIVE AWG20 BK
Latest revision:
/90.2 / 0V DRIVE BN
1
Prepared by, date:

2
-X3
BOARDS
5
24V SYS
CONTACTOR
AXIS / DRIVE /
/88.2 / +24V DRIVE;1 -463 AWG18 BU
3
POWER DISTRIBUTION BOARD
/88.2 / 0V DRIVE;1 -464 AWG18 BU
6
-G1
/37.1 / 24V I/O;1 -247 AWG16 BU
1
2
DC INPUT
-X1
-X2
-X4
AWG12 BU
I/O
24V I/O
/37.2 / 0V I/O;1 -248 AWG16 BU
3
1
1
Approved by, date:

CUSTOMER
POWER SUPPLY
4
2
2
3
4
/88.2 / +24V BRAKE;1 -466 AWG16 BU
1
-X1
4
3
/88.2 / +24V BRAKE;2 -465 AWG16 BU
2
AWG16 GNYE
3
/88.2 / +24V COOL;1 -469 AWG16 BU
3
3
4
-X5
5
UNIT
/88.2 / 0V BRAKE;1 -467 AWG16 BU
5
-X3
CONTACTOR
SIGNAL
AWG20 BU
INPUT
-X2
/88.2 / 0V BRAKE;2 -468 AWG16 BU

24V BRAKE / COOL
6
3
3
/88.2 / 0V COOL;1 -470 AWG16 BU

-153
-152
7
4
4
8
AWG16 BK
AWG16 BK
/38.2 / 24V SYS -250 AWG18 BU

1
4
/38.2 / 24V COOL -252 AWG18 BU

2
3
4
/50.2 / 24V PC;1 -301 AWG18

-XT16
Lab/Office:
/50.2 / 24V PC;2 -302 AWG18
6
L2
PC
-X6
/38.2 / 0V SYS -251 AWG18 BU

7
L2
PANELBOARD,
5
/38.2 / 0V COOL -253 AWG18 BU -309 BK 230V AC2;11 / /37.8

AWG16
8
L2
24V SYS, COOL, PC
-158 BK 230V AC2;12 / /37.3

AWG16
9
L2
JUMPER
-_158 BK 230V AC2;13 / /37.4

AWG16
L2
10
/50.2 / 0V PC;1 -303 AWG18

L2
11
/50.2 / 0V PC;2 -304 AWG18

L1
12
FOR SINGLE CABINET

L1
-308 BK 230V AC1;11 / /37.8

6
AWG16
L1
-157 BK 230V AC1;12 / /37.2

AWG16
-G3
L1
JUMPER
-_157 BK 230V AC1;13 / /37.4

AWG16
-X1
L1
24V CHARGE
1
1
24V CHARGE
2
2
L1
N.C.
3
3
N.C.
4
4
N.C.
-X7
5
5
0V
6
6
0V
ENERGY BANK
7
7
Status:
+SENSE
8
8
N.C.
ENERGY BANK
7
9
9
-F2
N.C.
Document no.
Approved
10
10
2008-07-17
/51.6 / USB2 +5V 2/RD 23

1
1
2
/51.6 / USB2 D- 1/WH 0V

Plant:
1/BK
-X8
1/GN
AC
/51.6 / USB2 D+
USB
23
MAIN
Location:
3
1_
3
3HAC024480-004
4
/51.6 / USB2_GND 2/BK 0V

2/BK
SC
4
COMPUTER
AC ;1
2_ //
SC 83
;1 .1
+ DM
8
/8
03
AWG16
//
/94.3 / +24V COOL;3 AWG20 BK 3.
5
83
1
RD
.1
= CAB.SC
/94.3 / +24V COOL;2 /8

-X9
/94.3 / 0V COOL;3 BN 3.
6
FAN
UNIT
DRIVE
/94.3 / 0V COOL;2 OG
MAIN FAN
4
Next 88
Rev. Ind Page 87
Total 153
1 2 3 4 5 6 7 8
CONTACTOR UNIT
-A43 -X5
PTC1 PTC1 / /112.3 /132.3 /152.3 /172.2
1 /122.3 /142.3 /162.3 /202.2
-X6
DRIVE /85.3 /87.2 /86.2 / 0V DRIVE;1
POWER 1 PTC1 ret PTC1 ret / /112.3 /132.3 /152.3 /172.2
SUPPLY /85.3 /87.1 /86.2 / +24V DRIVE;1 2 /122.3 /142.3 /162.3 /202.2
2
24VDrive
1 2 0V BRAKE 0V BRAKE;3 / /112.3 /132.3 /152.3 /172.2
24V 3
-X1 /122.3 /142.3 /162.3 /202.2
/41.7 / RUN_CH1
CONTROL /41.7 / RUN_CH1Ret 1 0V BRAKE OV BRAKE;4 / /112.3 /132.3 /152.3 /172.2
MODULE /41.7 / RUN_CH2 2 4 /122.3 /142.3 /162.3 /202.2
A21.X7 /41.7 / RUN_CH2Ret 3
-X10 SINGLE CABINET
4 -386 -380
AWG20 BU 1 2 AWG20 BU +24V COOL;4 / /178.2
-X22
LIM2 ch1 2 -387 -381
24VDrive 1 2
LIMIT LIM2 ch2 1 AWG20 BU AWG20 BU 0V COOL;4 / /178.2
RunCh2
SWITCH 2 3 1 -382
EXTERNAL LIM2 ch2 ret AWG20 BU FAN1 ret / /178.2
AWG20 BU
AWG20 BU
LIM2 ch1 ret 4 3
AXIS OPTION :
-389
-388
2
-E4 INTERNAL FAN
24VDrive 4 -A43
-X23
-X10.2 -365 -X1
LIMIT 1 AWG20 BU
3 1 3
M
OVERRIDE -366
AWG20 BU
BRAKE CTRL
4 2 1
24V COOL
2
AWG24 BU
AWG24 BU
-X21 DUAL CABINET
-736
-737
LIMIT /142.3 /152.3 /162.3 /92.1.7 / A43-X21:1 LIM1 ch1
SWITCH 1 /142.3 /152.3 /162.3 /92.1.7 / A43-X21:3 LIM1 ch2 1
3 RunCh1 -A43
CONTROL 1)
/142.3 /152.3 /162.3 /92.1.7 / A43-X21:4 LIM1 ch2 ret LIM2 -731 -734 -X10.1
CABLE 1 2
/142.3 /152.3 /162.3 /92.1.7 / A43-X21:2 LIM1 ch1 ret 4 LIM1 AWG24 BU AWG24 BU +24V COOL;4 / /177.1
0V COOL
1) Jumper if not used 2 -732 -735 2
AWG24 BU 1 2 AWG24 BU 0V COOL;4 / /177.1
-X1
CONTROL /41.7 / ENABLE2_1 -733 1
MODULE /41.7 / ENABLE2_1Ret 5 INTERLOCKING AWG24 BU FAN1 ret / /177.1
/89.2 / 0V COOL;6
/89.2 / BRAKE
A21.X7 /41.7 / SPEED 6 3
/41.7 / 0V 7 +24V COOL;5 / /177.1
8 0V COOL;5 / /177.1
PAN_CH1
24V COOL
/90.2 / RS485+ -X4 FAN2 ret / /177.1
0V COOL
BU
AXIS /90.2 / RS485- WHBU 4 K2
COMPUTER /90.2 / 0V ENABLE2 OG 5 RunCh1 K1 -X11
/90.2 / ENABLE2 WHOG 7 -383 AWG20 BU +24V COOL;5 / /178.2
8 RunCh2 2
-384 AWG20 BU 0V COOL;5 / /178.2
-X7
24V COOL
/85.3 /87.3 /86.3 / +24V BRAKE;2
0V COOL
1
PAN_CH2
1 -385 AWG20 BU FAN2 ret / /178.2
/85.4 /87.4 /86.4 / 0V COOL;1 3
DRIVE 2 SINGLE CABINET
POWER /85.4 /87.3 /86.3 / +24V COOL;1 4
/89.4 / LOCK1A
/89.4 / LOCK2B
/89.3 / SELF1
/89.4 / SELF2
/89.1 / 0V COOL;6
/89.2 / RCH1
3
SUPPLY -P1
/85.3 /87.3 /86.3 / +24V BRAKE;1
-X12 OPTION :
/89.2 / 0V COOL;6
/89.3 / RCH2
4 -491 AWG20 BU +24V
+ +
/85.4 /87.3 /86.4 / 0V BRAKE;2 1 DUTY
-492 TIME
/85.4 /87.3 /86.3 / 0V BRAKE;1
5
2
AWG20 BU
h COUNTER
6 0V
- -
CONTINUATION NEXT PAGE

CONTACTOR BOARD Approved
Sublocation: +
Next 89
Latest revision:
1
Prepared by, date:

-A43
-X8
-K42
-471 AWG20 BU 0V COOL;6 / /88.4
2
-472 AWG20 BU RCH1 / /88.5
A2
A1
CONTACTOR UNIT
-K44
-473 AWG20 BU 0V COOL;6 / /88.6
2
-474 AWG20 BU BRAKE / /88.6

5
A2
A1
Approved by, date:

-K43
-475 AWG20 BU 0V COOL;6 / /88.5
4
-476 AWG20 BU RCH2 / /88.5

3
A2
A1
-X3
-451 AWG20 BU
24V
-452 AWG20 BU BRAKE_FB

3
1
2
6
-479 AWG20 BU 0V
5
-493 AWG20 BU -480 AWG20 BU SELF1 / /88.4

44
43
4
-481 AWG20 BU
-H1
24V
10
STATUS DIOD
-494 AWG20 BU -482 AWG20 BU
DUAL CABINET
SELF2 / /88.4
44
43
9
-483 AWG20 BU LOCK1B

3
22
21
-484 AWG20 BU LOCK1A / /88.4

2
4
-485 AWG20 BU LOCK2A

7
22
21
-486 AWG20 BU LOCK2B / /88.4

8
EXT MON 1A
EXTCONT
EXT MON 1B &
-X24
34
33
EXT MON 2A
Lab/Office:
3
CUSTOMER
CONNECTION
EXT MON 2B 0V
4
34
33
5
5
24V
PTC2
-XS/XP40
1
AWG16 BU
EXT. LAMP
/202.2
/172.2
/162.3
/152.3
/142.3
/132.3
/122.3
/112.3
-445
1
POWER UNIT
PTC2 0V
2
-490
SERVO DISCONNECTOR
-X9
AWG16 BU BU BU AWG16 BU
BRAKEREL1
/202.2
/172.2
/162.3
/152.3
/142.3
/132.3
/122.3
/112.3
-447 -489 -487 24V BRAKE

4
3
6
14
13
13
14
2
1
-477 AWG16 BU 24V BRAKE

2
-448 AWG16 BU
3
CONTROL CABLE AND

BRAKEREL2
/202.2
/172.2
/162.3
/152.3
/142.3
/132.3
/122.3
/112.3
OPTION: EXTERNAL AXIS
AWG16 BU AWG16 BU
Status:
-446 -488 BRAKE PB

4
3
22
21
BRAKEPB
/202.2
/172.2
/162.3
/152.3
/142.3
/132.3
/122.3
/112.3
7
Document no.
Approved
AWG16 BU
2008-07-17
/ EXTBRAKEREL -449
6
5
-450 AWG16 BU
/ EXTBRAKEPB
6
Plant:
-F1
Location:
3HAC024480-004
Sublocation: +
/93.4 / L12 -128 AWG10 BK -122 BK -119 AWG10 BK T1_L1 / /83.2 /83.8
+ DM
8
2
1
2
1
I>
2
1
03
= CAB
Rev. Ind
/93.5 / L22 -129 AWG10 BK -123 BK -120 AWG10 BK T1_L2 / /83.2 /83.8
4
3
4
3
I>
4
3
AWG10 BK BK AWG10 BK
RECTIFIER
/93.5 / L32 -130 -124 -121 T1_L3 / /83.3 /83.8

6
5
6
5
I>
6
5
Next 90
Page 89
Total 153
1 2 3 4 5 6 7 8
DRIVE POWER /92.2 /92.1.2 / 0V DRIVE;2 -725 AWG20 ;
SUPPLY
/92.2 /92.1.2 / +24V DRIVE;2 -726 AWG20 BK;
EPS AXIS COMPUTER BOARD MAIN SERVO DRIVE UNIT
A44-X1 POWER SUPPLY EPS/ AXC -A42 -A41.1
-A42-X1
1
2
-X1
DRIVE POWER /85.2 /87.1 /86.1 / 0V DRIVE
SUPPLY 1
/85.1 /87.1 /86.1 / +24V DRIVE
2
-X11
1/BK
-X1
+FRAME RECEIVER
1 1
1/BN -FRAME RECEIVER
-X10
/85.5 /86.5 / 5V_OUT BK 2 2
1 2/BK +CLK RECEIVER
DRIVE POWER /85.5 /86.5 / ACOK BN 6 6
SUPPLY 2 2/RD -CLK RECEIVER

/85.6 /86.5 / BRAKEOK RD 7 7
3 3/BK +DATA RECEIVER
/85.6 /86.5 / TEMPOK OG 11 11
4 3/OG -DATA RECEIVER
12 12
4/BK +FRAME TRANSMITTER
3 3
1) 4/YE -FRAME TRANSMITTER
AWG24 -X2
/50.7 / TX+ 4 4
CONTROL 1 5/BK +CLK TRANSMITTER
MODULE /50.7 / TX- 8 8
2 5/GN -CLK TRANSMITTER
A31.A9
/50.7 / RX+ 9 9
MAIN
3 6/BK +DATA TRANSMITTER
COMPUTER /50.7 / RX- 13 13
6 6/BU -DATA TRANSMITTER
14 14
/92.6 /92.1.6 / _TX+ 7/BK GND
OPTION : 5 5
EPS OR /92.6 /92.1.6 / _TX- 7/VT +5V TRANCIVER SUPPLY

10 10
SAFE MOVE
/92.6 /92.1.6 / _RX+ 8/BK GND
A44-X4
15 15
/92.6 /92.1.6 / _RX-
-X6
/88.2 / RS485+
4
CONTACTOR /88.2 / RS485-
UNIT 5 -X3
/88.2 / 0V ENABLE2 /85.2 /87.1 /86.2 / 0V Drive sys
7 1
/88.2 / ENABLE2 /85.2 /87.1 /86.2 / 24V Drive sys
8 2
-X9
RXD
2
1) No connection to main computer if EPS or SAFE MOVE is connected TXD
3
0V
5

AXIS COMPUTER UNIT Approved
Sublocation: +
Next 91
1 2 3 4 5 6 7 8
OPTION : EPS
-A44
See page 92
AXIS COMPUTER BOARD
-A42 OPTION: SAFE MOVE DSQC647
-A44
See page 92.1
-X4
MRCO1 MRCO1 / /202.2 /162.3 /142.3 /122.3
1 /172.2 /152.3 /132.3 /112.3
MRCO1_N MRCO1_N / /202.2 /162.3 /142.3 /122.3

2 /172.2 /152.3 /132.3 /112.3
1) MRCI1 MRCI1 / /202.2 /162.3 /142.3 /122.3

4 /172.2 /152.3 /132.3 /112.3
-X8
GND_O2
1 MRCI1_N MRCI1_N / /202.2 /162.3 /142.3 /122.3 CONTROL
24V_EXT2 5 /172.2 /152.3 /132.3 /112.3 SIGNAL
2
0V MRC_0V;1 / /202.2 /162.3 /142.3 /122.3
3 6 /172.2 /152.3 /132.3 /112.3
IN 2
4 24V_SMB1 24V_SMB1 / /202.2 /162.3 /142.3 /122.3
7 /172.2 /152.3 /132.3 /112.3
5
IN 1 0V MRC_0V;2 / /202.2 /162.3 /142.3 /122.3
6 3 /172.2 /152.3 /132.3 /112.3
GND_01
PROCESS I/O 7 0V MRC_0V;3 / /202.2 /162.3 /142.3 /122.3
24V_EXT1 9 /172.2 /152.3 /132.3 /112.3
8
OUT 2
9
10 DRIVE
GND_I2 MODULE
11
-X5 -XS41
12 MRCO2
GND_I1 1 A
13 MRCO2_N
2 B
14 MRCI2
OUT 1 4 C
15 MRCI2_N EXT. AXIS
5 D SIGNAL
0V
6 E
24V_SMB2
7 F
0V
3 G
0V
9 J
1) -X8 ONLY ON DSQC 635

AXIS COMPUTER UNIT Approved
Sublocation: +
Next 92
1 2 3 4 5 6 7 8
OPTION : EPS DSQC 646

-A44
-X4
AWG24
BU _TX+ / /90.2
-X1 1
DRIVE POWER /90.2 / 0V DRIVE;2 WHBU _TX- / /90.2 AXIS
SUPPLY 1 2 COMPUTER
/90.2 / +24V DRIVE;2 OG _RX+ / /90.2 BOARD
2 3
A43-X2
WHOG _RX- / /90.2
4
-X6
MRCO1
AWG24 -X3 1
/50.7 / TX+ WHOG MRCO1-N
CONTROL 1 2
MODULE /50.7 / TX- OG MRCI1

2 4
A31.A9
/50.7 / RX+ WHGN MRCI1-N CONTROL
MAIN
3 5 SIGNAL
COMPUTER /50.7 / RX- GN 0V XS2
6 6
24V-SMB1
7
0V
3
0V
9
-X5 -X9
MRCO1 +24V
1 1
MRCO1-N 0V
2 2
MRCI1 UT1A
AXIS 4 3
COMPUTER MRCI1-N UT1B

5 4
BOARD
0V UT2A
A42-X4
6 5
24V-SMB1 UT2B PROCESS I/O
7 6
0V UT3A
3 7
0V UT3B
9 8
UT4A
9
UT4B
10
UT5A
11
UT5B
12
IN1A
13
IN1B
14

EPS Approved
Sublocation: +
Next 92.1
1 2 3 4 5 6 7 8
OPTION: SAFE MOVE DSQC647

-A44
-X13
Relay output RelOut 1A A43-X21:1 / /88.2
-X1
DRIVE POWER /90.2 / 0V DRIVE;2 pair 1 1
SUPPLY 1 RelOut 1B A43-X21:2 / /88.2

/90.2 / +24V DRIVE;2 2 CONTACTOR UNIT
2 Relay output RelOut 2A A43-X21:3 / /88.2 X21
pair 2 3
RelOut 2B A43-X21:4 / /88.2
4
AWG24
-X3 -X4
MAIN /50.7 / TX+ AWG24 WHOG WHOG _TX+ / /90.2 AXIS
COMPUTER /50.7 / TX- OG 1 1 OG _TX- / /90.2 COMPUTER
A31.A9 /50.7 / RX+ WHGN 2 2 WHGN _RX+ / /90.2 BOARD
3 3
CONTROL A43.X2
4 4
MODULE /50.7 / RX- GN 5 5 GN _RX- / /90.2
6 6
7 7
8 8
-X5 -X6
MRCO1 MRCO1
1 1
MRCO1-N MRCO1-N
2 2
AXIS MRCI1 MRCI1
COMPUTER 4 4 CONTROL
BOARD MRCI1-N MRCI1-N SIGNAL
5 5
A42-X4 XS2
0V 0V
6 6
24V-SMB1 24V-SMB1
7 7
0V 0V
3 3
0V 0V
9 9
-X7 -X8
MRCO2 MRCO2
1 1
MRCO2-N MRCO2-N
AXIS 2 2
COMPUTER MRCI2 MRCI2 EXT. AXIS

4 4 SIGNAL
BOARD
MRCI2-N MRCI2-N XS41
A42-X5
5 5
0V 0V
6 6
24V-SMB2 24V-SMB2
7 7
0V 0V
3 3
0V 0V
9 9

SAFE MOVE Approved
Next 92.2
1 2 3 4 5 6 7 8
OPTION: SAFE MOVE DSQC647

-A44
-X9 -X11
IN1A I/O POWER +24V I/O
1 SUPPLY 1
IN1B Equivalent GND
2 configurable 2
IN2A activation OUT1A
3 3
Inputs
IN2B OUT1B
4 4
IN3A Configurable OUT2A
5 Monitor 5
IN3B Outpurs OUT2B
6 6
IN4A OUT3A
7 7
IN4B OUT3B
8 8
IN5A OUT4A
9 Antivalent 9
IN5B configurable OUT4B
10 10
activation
IN6A
Inputs
11
PROCESS I/O IN6B PROCESS I/O
12
-X10 -X12
IN7A
1 Antivalent 1
IN7B configurable
2 2
activation
IN8A OUT5A
Inputs
3 3
IN8B OUT5B
4 4
CSC INA Antivalent OUT6A
5 Inputs Configurable 5
CSC INB Monitor OUT6B
6 6
Outpurs
OUT7A
7 7
OUT7B
8 8
OVR A Antivalent OUT8A
9 Inputs 9
OVR B OUT8B
10 10
11
12

SAFE MOVE Approved
Next 93
1 2 3 4 5 6 7 8
CONTACTOR UNIT
L12 / /89.8
L22 / /89.8
L32 / /89.8
AWG10 GNYE
MAIN SERVO DRIVE UNIT RECTIFIER
-A41.1 -A41.2 BLEEDER
-X32 1 2 3 4
-X33 -132 AWG12 BK

-192
1 GNYE
1 AWG12
-X2 -X30
Spare 1/BK -R1.1
Spare 1 1/BN 1
2
+24V 2 2/BK 2
0V 6 2/RD 6 -133 AWG12 BK
DATA_TO_DRIVE 7 3/BK 7 2
DATA_TO_DRIVE_N 11 3/OG 11
ENABLE 12 4/BK 12
ENABLE_N 3 4/YE 3
CLK 4 6/BU 4
CLK_N 8 5/GN 8
DATA_TO_RECT 9 5/BK 9
CAPACITOR UNIT
13 6/BK 13
-A41.3
DATA_TO_RECT_N
0V 14 7/BK 14
7/VT
-X31 -69 AWG20 BU
-X34
+5V 5 5
10 10 1 1
-70 AWG20 BU
2 2
-71 AWG20 BU
3 3
-72 AWG20 BU
4 4
DC-BUSBAR

RECTIFIER AND BLEEDER Approved
Sublocation: +
Next 94
1 2 3 4 5 6 7 8
FAN UNIT
-E1
-E1.XP2 -E1.XS2
-XS1 -354
/85.4 /87.8 /86.4 / +24V COOL;2
RD AWG24 BU
3 3 AWG24 3
/85.4 /87.8 /86.4 / +24V COOL;3 BK -350 AWG24 BU
1 1 1
-E41 -X1 -E42 -X1 -E43 -X1 -E44 -X1
1 1 1 1
+
DRIVE POWER M M M M
SUPPLY
- - - -
-X1 3 -X1 3 -X1 3 -X1 3
/85.4 /87.8 /86.4 / 0V COOL;3 BN -351 AWG24 BU

2 2 2
/85.5 /87.8 /86.4 / 0V COOL;2 OG -355 AWG24 BU
4 4 4

FAN UNIT Approved
Sublocation: +
Next 95
1 2 3 4 5 6 7 8
ADDITIONAL AXIS 1-3, DRIVE UNIT NO 7

MAIN SERVO DRIVE UNIT SINGLE SERVO DRIVE UNIT
-A41.1 -A41.1.3
-X7 -X20
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
16 16
17 17
19 19
20 20
21 21
22 22
15 15
23 23
18 18
24 24
25 25
26 26
DC-BUSBAR

ADDITIONAL AXIS 1-3, DRIVE UNIT NO 7 Approved
Sublocation: +
Next 96
1 2 3 4 5 6 7 8

-A41.1 -A41.1.4
-X8 -X20
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
24 24
25 25
26 26
DC-BUSBAR

Sublocation: +
Next 97
1 2 3 4 5 6 7 8

-A41.1 -A41.1.5
-X9 -X20
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
16 16
17 17
19 19
20 20
21 21
22 22
15 15
23 23
18 18
24 24
25 25
26 26
DC-BUSBAR

Sublocation: +
Next 98
1 2 3 4 5 6 7 8

-A41.1.3 -XS/XP7
-X21 -4000
R AWG12 BK
1 A1
R -4001 AWG12 BK
2 A2
T -4002 AWG12 BK
3 A3
T -4003 AWG12 BK
4 A4
S -4004 AWG12 BK
5 A5
S -4005 AWG12 BK
6 A6
CONTACTOR UNIT
-A43
-X24 -4013
PTC AWG16 BU
1 PTC 0V -4014 AWG16 BU E1
2 E2
3
4
5 E3
6
E4
-X5 -A43.XP5
PTC1
1 1 E5
PTC1 ret
2 2 E6
3 3 F9
0V BRAKE
4 4 F10
0V BRAKE -4012 AWG16 BU
F11
-X22 -4006
LIM2 ch1 AWG16 BU
1 F1
LIM2 ch1 ret -4007 AWG16 BU
2 F4
LIM2 ch2 -4008 AWG16 BU
3 F2
LIM2 ch2 ret -4009 AWG16 BU
4 F3
-XS40 EXT.LAMP
-445
1 -447 BRAKE REL F5
2 -448 BRAKE REL
3 -446 BRAKE PB F6
4 BRAKE REL. +24V -4010 AWG16 BU
5 BRAKE PB -4011 AWG16 BU F7
6
DRIVE MODULE F8
X40 -XP40 AWG16 BU AWG10 GNYE

1
AWG16 BU
2
AWG16 BU
3
AWG16 BU
4

EXTERNAL AXIS no 7 Approved
Next 99
1 2 3 4 5 6 7 8

-A41.1.4
FOR 8 AXIS
-XS/XP7
-X21 -4000
R BK
1 B1
R -4001 BK
2 B2
T -4002 BK
3 B3
T -4003 BK
4 B4
S -4004 BK
5 B5
S -4005 BK
6 B6

-A41.1.5
FOR 9 AXIS
ONLY
IRB140, 260, 340, 360
IRB1400, 2400 -XS/XP7
-X21 -4000
R BK
1 C1
R -4001 BK
2 C2
T -4002 BK
3 C3
T -4003 BK
4 C4
S -4004 BK
5 C5
S -4005 BK
6 C6

EXTERNAL AXIS no 8 - 9 Approved
Next 110
1 2 3 4 5 6 7 8
IRB140 cabinet module

Sublocation +140

IRB 140 CABINET MODULE Approved
Sublocation: + 140
Next 111
Latest revision:
1
Prepared by, date:

-A41.1
=MAN+R1-MP 1-3
-XS/XP1
-X17
M3R BUGN -_400 AWG14 BK

1
13
A1
M3S BURD -_402 AWG14 BK
2
17
A3
M3T BUWH -_404 AWG14 BK
2
15
A5
MAIN SERVO DRIVE UNIT
M1T BKRD -_410 AWG14 BK

4
3
A11
Approved by, date:

M1S BKGN -_408 AWG14 BK
5
5
A9
M1R BKBU -_406 AWG14 BK
6
1
A7
DC-BUSBAR
3
=MAN+R1-MP 4-6
-X18
M6R BN -_418 AWG14 BK

1
6
B3
M6S GNRD -_420 AWG14 BK

2
9
B4
M6T GNWH -_422 AWG14 BK

3
12
B5
M4T BNBU -_432 AWG14 BK

4
3
B11
M4S BNBK -_430 AWG14 BK

5
2
4
B10
M4R BU -_428 AWG14 BK

6
1
B9
Lab/Office:
-X19
M2R BKWH -_412 AWG14 BK

1
7
A13
M2S BK -_414 AWG14 BK

2
11
A15
5
M2T BUBK -_416 AWG14 BK

3
9
B1
IRB 140
M5T BNWH -_426 AWG14 BK
4
10
B8
M5S BNRD -_425 AWG14 BK

5
7
B7
M5R BNGN -_424 AWG14 BK

6
4
B6
SERVO DRIVE SYSTEM

AWG10 GNYE
6
AWG10 GNYE
Status:
7
Document no.
Approved
Plant: 2008-07-17
Location:
3HAC024480-004
MANIPULATOR
DRIVE MODULE
+ DM
8
Sublocation: + 140
03
= CAB
Rev. Ind
Total 153
Next 112
Page 111
1 2 3 4 5 6 7 8
DRIVE MANIPULATOR
MODULE
=MAN+R2-SMB
-XS/XP2
/91.6 / MRCO1 WH SDI
/91.6 / MRCO1_N A BU 9 SDI-N
/91.6 / MRCI1 B WH 5 SDO
/91.6 / MRCI1_N C OG 8 SDO-N
AXIS COMPUTER BOARD /91.6 / MRC_0V;1 D WH 4 0V SERIAL
A42-X4 E WH 3 MEASUREMENT
/91.6 / 24V_SMB1 GN 24V BOARD
F BN 7
/91.6 / MRC_0V;2
G
/91.6 / MRC_0V;3 H
J GY BATSUP
K RD 6 BATLD
L 2
=MAN+R1-H1
-_433 -XS/XP1
/89.5 AWG16 OG
EXT. LAMP C7 1 =MAN+R1-MP 4-6

DRIVE MODULE /89.7 -_434 AWG16 BU OGWH
X40 BRAKEPB B16 15

/89.6 -_435 AWG16 BU GYBK
BRAKEREL1 B12 8
/89.6 -_436 AWG16 BU GYBU
BRAKEREL2 B13 5
/88.7 -_438 AWG16 BU GYGN
/ OV BRAKE;4 B14 13
CONTACTOR UNIT /88.7 -_439 AWG16 BU OGBU
A43-X5 / PTC1 C2 11
=MAN+R1-MP 1-3
/88.7 -_440 AWG16 BU OGBK
/ PTC1 ret C1 2
/88.7 -_437 AWG16 BU OGRD
/ 0V BRAKE;3 B15 14
GYWH
D2 10
GYRD
D1 16
GY
D3 18
OGGN
D4 12

CONTROL CABLE Approved
Sublocation: + 140
IRB 140
Next 113
1 2 3 4 5 6 7 8
CONTROL
MODULE MANIPULATOR
IRB 140
Customer
Connection
-XS/XP5
-XP/XT5 =MAN+R1-CS
-625 AWG24 OG CSA
1 B5 1
-626 AWG24 OG CSB
2 C5 9
-627 AWG24 OG CSC
3 D5 2
-628 AWG24 OG CSD
4 A6 10
-629 AWG24 OG CSE
5 B6 3
-630 AWG24 OG CSF
6 C6 11
-631 AWG24 OG CSG
7 D6 4
-632 AWG24 OG CSH
8 A7 12
-633 AWG24 OG CSJ
9 B7 5
-634 AWG24 OG CSK
10 C7 13
-635 AWG24 OG CSL
11 D7 6
-636 AWG24 OG CSM
12 A8 14

CUSTOMER SIGNAL Approved
Sublocation: + 140
DUAL CABINET
Next 114
Prepared by, date: Approved by, date: IRB 140 3HAC024480-004 03 Total 153
1 2 3 4 5 6 7 8
CONTROL
MODULE MANIPULATOR
IRB 140
Customer
Connection
-XS/XP5
-708
-XP/XT5 AWG24
=MAN+R1-CS
BK CSA
1 B5 1
BN CSB
2 C5 9
RD CSC
3 D5 2
OG CSD
4 A6 10
YE CSE
5 B6 3
GN CSF
6 C6 11
BU CSG
7 D6 4
VT CSH
8 A7 12
GY CSJ
9 B7 5
WH CSK
10 C7 13
WH/BK CSL
11 D7 6
WH/BN CSM
12 A8 14

Sublocation: + 140
SINGLE CABINET
Next 120
1 2 3 4 5 6 7 8
IRB340 and IRB360 cabinet module

Sublocation +340

IRB 340 AND IRB360 CABINET MODULE Approved
Sublocation: + 340
Next 121
Latest revision:
1
Prepared by, date:

2
-A41.1
Approved by, date:

=MAN+R1-MP 1-3
-XS/XP1
-X17
BKWH M2R -_400 AWG16 BK

1
9
A11
BK M2S -_402 AWG16 BK
11
A9
BUBK M2T -_404 AWG16 BK
3
7
A7
BKRD M1T -_410 AWG16 BK
4
=MAN+R1-MP 4-6
A5
BKGN M1S -_408 AWG16 BK
5
1
B3
BKBU M1R -_406 AWG16 BK
6
2
B4
4
-X19
DC-BUSBAR
BUGN M3R -_418 AWG16 BK

1
9
B10
BURD M3S -_420 AWG16 BK

2
6
B9
BUWH M3T -_422 AWG16 BK

3
10
B8
BNBU M4T -_416 AWG16 BK

4
Lab/Office:
13
A13
BNBK M4S -_414 AWG16 BK

5
17
A15
BU M4R -_412 AWG16 BK

6
15
B1
5
AWG10 GNYE
AWG10 GNYE
IRB 340 AND IRB360

SERVO DRIVE UNITS
6

Status:
7
Document no.
Approved
DRIVE MODULE
2008-07-17
MANIPULATOR
Plant:
Location:
3HAC024480-004
+ DM
8
Sublocation: + 340
03
= CAB
Rev. Ind
Total 153
Next 122
Page 121
1 2 3 4 5 6 7 8
DRIVE MODULE MANIPULATOR
=MAN+R2-SMB
-XS/XP2
/91.6 / MRCO1 SDI
/91.6 / MRCO1_N A 9 SDI-N
/91.6 / MRCI1 B 5 SDO
/91.6 / MRCI1_N C 8 SDO-N
AXIS COMPUTER BOARD /91.6 / MRC_0V;1 D 4 0V SERIAL
A42-X4 E 3 MEASUREMENT
/91.6 / 24V_SMB1 24V BOARD
F 7
/91.6 / MRC_0V;2
G
/91.6 / MRC_0V;3 H
J BATSUP
K 6 BATLD
L 2
=MAN+R1-H1
-_433 -XS/XP1
/89.5 AWG16 BU GY
EXT. LAMP C7 1
-_434 =MAN+R1-MP 4-6
/89.7 AWG16 BU GNWH
DRIVE MODULE BRAKEPB B16 15
X40 /89.6 -_435 AWG16 BU BNRD
BRAKEREL1 B12 8
/89.6 -_436 AWG16 BU BNGN
BRAKEREL2 B13 5
/88.7 -_438 AWG16 BU BNWH
/ OV BRAKE;4 B14 13
CONTACTOR UNIT /88.7 -_439 AWG16 BU BN
A43-X5 / PTC1 C2 11
-_440 =MAN+R1-MP 1-3
/88.7 AWG16 BU GYBK
/ PTC1 ret C1 2
/88.7 -_437 AWG16 BU GNRD
/ 0V BRAKE;3 B15 14
GYBU
D2 10
GYRD
D1 16
GYWH
D3 18
GYGN
D4 12

Sublocation: + 340
IRB 340 AND IRB360
Next 123
1 2 3 4 5 6 7 8
CONTROL MODULE
Customer MANIPULATOR
Connection IRB 340
-XS/XP5
-XP/XT5
-625 =MAN+R1-CS
AWG24 OG CSA
1 B5 A
-626 AWG24 OG CSB
2 C5 B
-627 AWG24 OG CSC
3 D5 C
-628 AWG24 OG CSD
4 A6 D
-629 AWG24 OG CSE
5 B6 E
-630 AWG24 OG CSF
6 C6 F
-631 AWG24 OG CSG
7 D6 G
-632 AWG24 OG CSH
8 A7 H
-633 AWG24 OG CSJ
9 B7 J
-634 AWG24 OG CSK
10 C7 K
-635 AWG24 OG CSL
11 D7 L
-636 AWG24 OG CSM
12 A8 M

Sublocation: + 340
DUAL CABINET
Next 124
Prepared by, date: Approved by, date: IRB 340 AND IRB360 3HAC024480-004 03 Total 153
1 2 3 4 5 6 7 8
CONTROL MODULE
Connection IRB 340
-XS/XP5
-708
-XP/XT5 AWG24
=MAN+R1-CS
BK CSA
1 B5 A
BN CSB
2 C5 B
RD CSC
3 D5 C
OG CSD
4 A6 D
YE CSE
5 B6 E
GN CSF
6 C6 F
BU CSG
7 D6 G
VT CSH
8 A7 H
GY CSJ
9 B7 J
WH CSK
10 C7 K
WH/BK CSL
11 D7 L
WH/BN CSM
12 A8 M

Sublocation: + 340
SINGLE CABINET
Next 130
Prepared by, date: Approved by, date: IRB 340 AND IRB360 3HAC024480-004 03 Total 153
1 2 3 4 5 6 7 8

Sublocation +1400

Sublocation: + 1400
Next 131
Latest revision:
1
Prepared by, date:

-A41.1
=MAN+R1-MP
-XS/XP1
-X17
A1
A1
2
A2
A3
2
A3
A5

4
D2
A11
Approved by, date:

5
A9
D1
6
A4
A7
3
-X18

1
B3
A10
DC-BUSBAR
A9
B4
M4T BNBU -_422 AWG14 BK
3
A8
B5

4
B10
B11

5
4
D7
B10

6
B9
D8
Lab/Office:
-X19

1
D3
A13

2
D4
A15
5

3
B1
B1
IRB 1400
4
B8
D9

5
B7
D10

6
A7
B6
SERVO DRIVE SYSTEM

AWG10 GNYE
6
AWG10 GNYE
Status:
7
Document no.
Approved
DRIVE MODULE
2008-07-17
MANIPULATOR
Plant:
Location:
3HAC024480-004
+ DM
8
03
= CAB
Sublocation: + 1400
Rev. Ind
Total 153
Next 132
Page 131
1 2 3 4 5 6 7 8
=MAN+R1-SMB
-XS/XP2
/91.6 / MRCO1 SDI
/91.6 / MRCO1_N A A SDI-N
/91.6 / MRCI1 B B SDO
/91.6 / MRCI1_N C C SDO-N
AXIS COMPUTER BOARD /91.6 / MRC_0V;1 D D 0V SERIAL
A42-X4 E E MEASUREMENT
/91.6 / 24V_SMB1 24V BOARD
F F
/91.6 / MRC_0V;2
G G
/91.6 / MRC_0V;3 H H 0V
J J BATSUP
K K BATLD
L L
=MAN+R1-MP
-_433 -XS/XP1
/89.5 AWG16 OG
EXT. LAMP C7 C7
/89.7 -_434 AWG16 BU OGWH
DRIVE MODULE BRAKEPB B16 B8
X40 /89.6 -_435 AWG16 BU GYBK
BRAKEREL1 B12 C9
/89.6 -_436 AWG16 BU GYBU
BRAKEREL2 B13 C8
/88.7 -_438 AWG16 BU GYGN
/ OV BRAKE;4 B14 C10

A43-X5 / PTC1 C2 B9
/88.7 -_440 AWG16 BU OGBK
/ PTC1 ret C1 B2
/88.7 -_437 AWG16 BU OGRD
/ 0V BRAKE;3 B15 B7
GYWH
D2 B3
GYRD
D1 B4
GY
D3 C2
OGGN
D4 C1

Sublocation: + 1400
IRB 1400
Next 133
1 2 3 4 5 6 7 8
CONTROL MODULE
Connection IRB 1400
-XS/XP5
-XP/XT5 =MAN+R1-CS
-625 AWG24 OG CSA
1 B5 A
-626 AWG24 OG CSB
2 C5 B
-627 AWG24 OG CSC
3 D5 C
-628 AWG24 OG CSD
4 A6 D
-629 AWG24 OG CSE
5 B6 E
-630 AWG24 OG CSF
6 C6 F
-631 AWG24 OG CSG
7 D6 G
-632 AWG24 OG CSH
8 A7 H
-633 AWG24 OG CSJ
9 B7 J
-634 AWG24 OG CSK
10 C7 K
-635 AWG24 OG CSL
11 D7 L
-636 AWG24 OG CSM
12 A8 M

CUSTOMER SIGNALS Approved
Sublocation: + 1400
DUAL CABINET
Next 134
1 2 3 4 5 6 7 8
CONTROL MODULE
Connection IRB 1400
-XS/XP5
-XP/XT5 =MAN+R1-CS
-708
AWG24 BK CSA
1 B5 A
BN CSB
2 C5 B
RD CSC
3 D5 C
OG CSD
4 A6 D
YE CSE
5 B6 E
GN CSF
6 C6 F
BU CSG
7 D6 G
VT CSH
8 A7 H
GY CSJ
9 B7 J
WH CSK
10 C7 K
WH/BK CSL
11 D7 L
WH/BN CSM
12 A8 M

CUSTOMER SIGNALS Approved
Sublocation: + 1400
SINGLE CABINET
Next 135
1 2 3 4 5 6 7 8
CONTROL MODULE
Connection IRB 1400
-XS/XP8
-XP/XT8 =MAN+R1-SW
-601 OG
1 A A
-602 OG
2 B B
-603 OG
3 C C
-604
OG
4 D D
-605 OG
5 E E
-606 OG
6 F F
-607 OG
7 J J
-608 OG
8 K K
-609 OG
9 L L
-610 OG
10 M M
-611 OG
11 G G
-612 OG
12 H H

POSITION SWITCHES Approved
Sublocation: + 1400
DUAL CABINET
Next 136
1 2 3 4 5 6 7 8
CONTROL MODULE
Connection IRB 1400
-XS/XP8
-XP/XT8 =MAN+R1-SW
-705
AWG24 BK
1 A A
BN
2 B B
RD
3 C C
OG
4 D D
YE
5 E E
GN
6 F F
BU
7 J J
VT
8 K K
GY
9 L L
WH
10 M M
WH/BK
11 G G
WH/BN
12 H H

POSITION SWITCHES Approved
Sublocation: + 1400
SINGLE CABINET
Next 140
1 2 3 4 5 6 7 8

Sublocation +1600

Sublocation: + 1600
Next 141
Latest revision:
1
Prepared by, date:

-A41.1
0,00
32
=MAN+R1-MP
-XS/XP1
-X17
1
A1
A1
2
A2
A3

2
A3
A5
4
D2
A11
Approved by, date:

5
A9
D1
6
A4
A7
3
-X18

1
B3
A10
2
A9
B4
BNBU AWG14 BK
DC-BUSBAR
M4T -_422
3
A8
B5

4
B10
B11

5
4
D7
B10

6
B9
D8
Lab/Office:
-X19

1
D3
A13

2
D4
A15
5

3
B1
B1
IRB 1600
4
B8
D9

5
B7
D10

6
A7
B6
SERVO DRIVE UNIT

AWG10 GNYE
6
AWG10 GNYE
Status:
7
Document no.
Approved
2008-07-17
MANIPULATOR
DRIVE MODULE
Plant:
Location:
3HAC024480-004
+ DM
8
03
= CAB
Sublocation: + 1600
Rev. Ind
Total 153
Next 142
Page 141
1 2 3 4 5 6 7 8
=MAN+R1-SMB
-XS/XP2
/91.6 / MRCO1 SDI
/91.6 / 24V_SMB1 24V BOARD
F F
/91.6 / MRC_0V;2
G
/91.6 / MRC_0V;3 H 0V
J J BATSUP
K K BATLD
L L
KEYPIN
M
=MAN+R1-MP
-_433 -XS/XP1
/89.5 AWG16 BU OG
EXT. LAMP C7 C7
/89.7 -_434 AWG16 BU OGWH
DRIVE MODULE BRAKEPB B16 B8
X40 /89.6 -_435 AWG16 BU GYBK
BRAKEREL1 B12 C9
/89.6 -_436 AWG16 BU GYBU
BRAKEREL2 B13 C8
/88.7 -_438 AWG16 BU GYGN

A43-X5 / PTC1 C2 B9
/88.7 -_440 AWG16 BU OGBK
/ PTC1 ret C1 B2
/88.7 -_437 AWG16 BU OGRD
/ 0V BRAKE;3 B15 B7
/88.2 / A43-X21:2 LIM 1A -_441 AWG16 BU GYWH

D2 B3
CONTACTOR UNIT /88.2 / A43-X21:4 LIM 2A -_442 AWG16 BU GYRD
A43-X21 D1 B4
/88.2 / A43-X21:3 LIM 2B -_443 AWG16 BU GY
D3 C2
/88.2 / A43-X21:1 LIM 1B -_444 AWG16 BU OGGN
D4 C1

Sublocation: + 1600
IRB 1600
Next 143
1 2 3 4 5 6 7 8
CONTROL MODULE
MANIPULATOR
Customer IRB 1600
-XS/XP5
Connection -XP/XT6
-648 AWG18 OG
=MAN+R1-CP/CS
CPA
1 -649 AWG18 OG A1 A1 CPB
2 -650 AWG18 OG B1 B1 CPC
3 -651 AWG18 OG C1 C1 CPD
4 -652 AWG18 OG D1 D1 CPE
5 -653 AWG18 OG A2 A2 CPF
6 -654 AWG18 OG B2 B2 CPJ
7 -655 AWG18 OG C2 C2 CPK
8 -656 AWG18 OG D2 D2 CPH
9 -657 AWG18 OG A3 A3
10 -658 AWG18 OG B3 B3
11 -659 AWG18 OG C3 C3
12 D3 D3
-XP/XT5.1
-625 AWG24 OG CSA

1 -626 AWG24 OG B5 B5 CSB
2 -627 AWG24 OG C5 C5 CSC
3 -628 AWG24 OG D5 D5 CSD
4 -629 AWG24 OG A6 A6 CSE
5 -630 AWG24 OG B6 B6 CSF
6 -631 AWG24 OG C6 C6 CSG
7 -632 AWG24 OG D6 D6 CSH
8 -633 AWG24 OG A7 A7 CSJ
9 -634 AWG24 OG B7 B7 CSK
10 -635 AWG24 OG C7 C7 CSL
11 -636 AWG24 OG D7 D7 CSM
12 A8 A8
-XP/XT5.2
-637 AWG24 OG CSN
13 -638 AWG24 OG B8 B8 CSP
14 -639 AWG24 OG C8 C8 CSR
15 -640 AWG24 OG D8 D8 CSS
16 -641 AWG24 OG A9 A9 CST
17 -642 AWG24 OG B9 B9 CSU
18 -643 AWG24 OG C9 C9 CSV
19 -644 AWG24 OG D9 D9 CSW
20 -645 AWG24 OG A10 A10 CSX
21 -646 AWG24 OG B10 B10 CSY
22 -647 AWG24 OG C10 C10 CSZ
23 D10
C10 D10

CUSTOMER POWER/SIGNAL Approved
Sublocation: + 1600
DUAL CABINET
Next 144
1 2 3 4 5 6 7 8
CONTROL MODULE MANIPULATOR

Customer IRB 1600
-XS/XP5
Connection -XP/XT6 -709
AWG24
BK
=MAN+R1-CP/CS
1 1 CPA
2 2 BN A1 A1 CPB
3 3 RD B1 B1 CPC
4 4 OG C1 C1 CPD
5 5 YE D1 D1 CPE
6 6 GN A2 A2 CPF
7 7 BU B2 B2 CPJ
8 8 VT C2 C2 CPK
9 9 GY D2 D2 CPH
10 10 WH A3 A3
11 11 WH/BK B3 B3
12 12 WH/BN C3 C3
D3 D3
-XP/XT5.1
-710
1 1 AWG24 BK CSA
2 2 BN B5 B5 CSB
3 3 RD C5 C5 CSC
4 4 OG D5 D5 CSD
5 5 YE A6 A6 CSE
6 6 GN B6 B6 CSF
7 7 BU C6 C6 CSG
8 8 VT D6 D6 CSH
9 9 GY A7 A7 CSJ
10 10 WH B7 B7 CSK
11 11 WH/BK C7 C7 CSL
12 12 WH/BN D7 D7 CSM
A8 A8
-XP/XT5.2
13 13 WH/RD CSN
14 14 WH/OG B8 B8 CSP
15 15 WH/YE C8 C8 CSR
16 16 WH/GN D8 D8 CSS
17 17 WH/BU A9 A9 CST
18 18 WH/VT B9 B9 CSU
19 19 WH/GY C9 C9 CSV
20 20 BN/BK D9 D9 CSW
21 21 BN/RD A10 A10 CSX
22 22 BN/OG B10 B10 CSY
23 23 BN/YE C10 C10 CSZ
D10
C10 D10

Sublocation: + 1600
SINGLE CABINET
Next 145
1 2 3 4 5 6 7 8
CONTROL MODULE
Connection IRB 1600
-XS/XP8
-XP/XT8
-_601 OG
=MAN+R1-SW
1 A A
-_602 OG
2 B B
-_603 OG
3 C C
-_604
OG
4 D D
-_605 OG
5 E E
-_606 OG
6 F F
-_607 OG
7 J J
-_608 OG
8 K K
-_609 OG
9 L L
-_610 OG
10 M M
-_611 OG
11 G G
-_612 OG
12 H H

POSITION SWITCH Approved
Sublocation: + 1600
DUAL CABINET
Next 146
1 2 3 4 5 6 7 8
CONTROL MODULE
Connection IRB 1600
-XS/XP8
-XP/XT8
-705
AWG24 BK
=MAN+R1-SW
1 A A
BN
2 B B
RD
3 C C
OG
4 D D
YE
5 E E
GN
6 F F
BU
7 J J
VT
8 K K
GY
9 L L
WH
10 M M
WH/BK
11 G G
WH/BN
12 H H

Sublocation: + 1600
SINGLE CABINET
Next 150
1 2 3 4 5 6 7 8
IRB260 and IRB2400 cabinet module

Sublocation +2400

IRB 260 and IRB 2400 CABINET MODULE Approved
Sublocation: + 2400
Next 151
Latest revision:
1
Prepared by, date:

-A41.1
32
=MAN+R1-MP
-XS/XP1
-X17
M1R BKBU -400 AWG14 BK
1
A1
A1
M1S BKGN -402 AWG14 BK
2
A2
A3
M1T BKRD -404 AWG14 BK

2
A3
A5
M2T BUBK -410 AWG14 BK
4
D2
A11
Approved by, date:

M2S BK -408 AWG14 BK
5
A9
D1
M2R BKWH -406 AWG14 BK
6
A4
A7
3
-X18
M4R BU -418 AWG14 BK

1
B3
A10
M4S BNBK -420 AWG14 BK
2
A9
B4
BNBU AWG14 BK
DC-BUSBAR
M4T -422
3
A8
B5
M6T GNRD -432 AWG14 BK

4
B10
B11
M6S GNWH -430 AWG14 BK

5
4
D7
B10
M6R BN -428 AWG14 BK

6
B9
D8
Lab/Office:
-X19
M3R BUGN -412 AWG14 BK

1
D3
A13
M3S BURD -414 AWG14 BK

2
D4
A15
5
M3T BUWH -416 AWG14 BK

3
B1
B1
M5T BNWH -426 AWG14 BK
IRB 2400
4
B8
D9
M5S BNRD -425 AWG14 BK

5
B7
D10
M5R BNGN -424 AWG14 BK

6
A7
B6
SERVO DRIVE UNIT

AWG10 GNYE
6
AWG10 GNYE
Status:
7
Document no.
Approved
2008-07-17
MANIPULATOR
DRIVE MODULE
Plant:
Location:
3HAC024480-004
+ DM
8
03
= CAB
Sublocation: + 2400
Rev. Ind
Total 153
Next 152
Page 151
1 2 3 4 5 6 7 8
=MAN+R1-SMB
-XS/XP2
/91.6 / MRCO1 SDI
/91.6 / 24V_SMB1 24V BOARD
F F
/91.6 / MRC_0V;2
G
/91.6 / MRC_0V;3 H 0V
J J BATSUP
K K BATLD
L L
KEYPIN
M
=MAN+R1-MP
-433 -XS/XP1
/89.5 AWG16 BU OG
DRIVE MODULE EXT. LAMP C7 C7
X40 /89.7 -434 AWG16 BU OGWH
BRAKEPB B16 B8
/89.6 -435 AWG16 BU GYBK
BRAKEREL1 B12 C9
/89.6 -436 AWG16 BU GYBU
BRAKEREL2 B13 C8
/88.7 -438 AWG16 BU GYGN

CONTACTOR UNIT /88.7 -439 AWG16 BU OGBU
A43-X5 / PTC1 C2 B9
/88.7 -440 AWG16 BU OGBK
/ PTC1 ret C1 B2
/88.7 -437 AWG16 BU OGRD
/ 0V BRAKE;3 B15 B7
/88.2 / A43-X21:2 LIM 1A -441 AWG16 BU GYWH

D2 B3
CONTACTOR UNIT /88.2 / A43-X21:4 LIM 2A -442 AWG16 BU GYRD
A43-X21 D1 B4
/88.2 / A43-X21:3 LIM 2B -443 AWG16 BU GY
D3 C2
/88.2 / A43-X21:1 LIM 1B -444 AWG16 BU OGGN
D4 C1

Sublocation: + 2400
IRB 2400
Next 153
1 2 3 4 5 6 7 8

Customer IRB 2400
-XS/XP5
Connection -XP/XT6
-648 AWG18 OG
=MAN+R1-CP/CS
CPA
1 -649 AWG18 OG A1 A1 CPB
2 -650 AWG18 OG B1 B1 CPC
3 -651 AWG18 OG C1 C1 CPD
4 -652 AWG18 OG D1 D1 CPE
5 -653 AWG18 OG A2 A2 CPF
6 -654 AWG18 OG B2 B2 CPJ
7 -655 AWG18 OG C2 C2 CPK
8 -656 AWG18 OG D2 D2 CPL
9 -657 AWG18 OG A3 A3 CPM
10 -658 AWG18 OG B3 B3
11 -659 AWG18 OG C3 C3
12 D3 D3
-XP/XT5.1
-625 AWG24 OG CSA

1 -626 AWG24 OG B5 B5 CSB
2 -627 AWG24 OG C5 C5 CSC
3 -628 AWG24 OG D5 D5 CSD
4 -629 AWG24 OG A6 A6 CSE
5 -630 AWG24 OG B6 B6 CSF
6 -631 AWG24 OG C6 C6 CSG
7 -632 AWG24 OG D6 D6 CSH
8 -633 AWG24 OG A7 A7 CSJ
9 -634 AWG24 OG B7 B7 CSK
10 -635 AWG24 OG C7 C7 CSL
11 -636 AWG24 OG D7 D7 CSM
12 A8 A8
-XP/XT5.2
-637 AWG24 OG CSN
13 -638 AWG24 OG B8 B8 CSP
14 -639 AWG24 OG C8 C8 CSR
15 -640 AWG24 OG D8 D8 CSS
16 -641 AWG24 OG A9 A9 CST
17 -642 AWG24 OG B9 B9 CSU
18 -643 AWG24 OG C9 C9 CSV
19 -644 AWG24 OG D9 D9 CSW
20 -645 AWG24 OG A10 A10 CSX
21 -646 AWG24 OG B10 B10 CSY
22 -647 AWG24 OG C10 C10 CSZ
23 D10
C10 D10

Sublocation: + 2400
DUAL CABINET
Next 154
1 2 3 4 5 6 7 8

Customer IRB 2400
-XS/XP5
Connection -XP/XT6 -709
AWG24
BK
=MAN+R1-CP/CS
1 1 CPA
2 2 BN A1 A1 CPB
3 3 RD B1 B1 CPC
4 4 OG C1 C1 CPD
5 5 YE D1 D1 CPE
6 6 GN A2 A2 CPF
7 7 BU B2 B2 CPJ
8 8 VT C2 C2 CPK
9 9 GY D2 D2 CPL
10 10 WH A3 A3 CPM
11 11 WH/BK B3 B3
12 12 WH/BN C3 C3
D3 D3
-XP/XT5.1
-710
1 1 AWG24 BK CSA
2 2 BN B5 B5 CSB
3 3 RD C5 C5 CSC
4 4 OG D5 D5 CSD
5 5 YE A6 A6 CSE
6 6 GN B6 B6 CSF
7 7 BU C6 C6 CSG
8 8 VT D6 D6 CSH
9 9 GY A7 A7 CSJ
10 10 WH B7 B7 CSK
A8 A8
-XP/XT5.2
13 13 WH/RD CSN
21 21 BN/RD A10 A10 CSX
22 22 BN/OG B10 B10 CSY
23 23 BN/YE C10 C10 CSZ
D10
C10 D10

Sublocation: + 2400
SINGLE CABINET
Next 155
1 2 3 4 5 6 7 8
CONTROL MODULE
Connection IRB 2400
-XS/XP8
-XP/XT8
-_601 OG
=MAN+R1-SW
1 A A
-_602 OG
2 B B
-_603 OG
3 C C
-_604
OG
4 D D
-_605 OG
5 E E
-_606 OG
6 F F
-_607 OG
7 J J
-_608 OG
8 K K
-_609 OG
9 L L
-_610 OG
10 M M
-_611 OG
11 G G
-_612 OG
12 H H

Sublocation: + 2400
DUAL CABINET
Next 156
1 2 3 4 5 6 7 8
CONTROL MODULE
Connection IRB 2400
-XS/XP8
-XP/XT8
-705
AWG24 BK
=MAN+R1-SW
1 A A
BN
2 B B
RD
3 C C
OG
4 D D
YE
5 E E
GN
6 F F
BU
7 J J
VT
8 K K
GY
9 L L
WH
10 M M
WH/BK
11 G G
WH/BN
12 H H

Sublocation: + 2400
SINGLE CABINET
Next 160
1 2 3 4 5 6 7 8

Sublocation +4400

Sublocation: + 4400
Next 161
Latest revision:
1
Prepared by, date:

-A41.1
=MAN+R1-MP
-XS/XP1
-X11
M1R BKBU -_400 AWG16
1
M1R BKGN -_401 AWG16
A1
A1
2
M1T BUGN -_402 AWG16
A2
A2
3
M1T BURD -_403 AWG16
A5
A5
4
M1S BKWH -_404 AWG16
A6
A6
5
M1S BK -_405 AWG16
A3
A3
6
M1R BKRD
A4
A4
M1S BUBK
D6
D6
2
M1T BUWH
D8
D8
D10
D10
Approved by, date:

-X12
M4R GYWH -_418 AWG16 BK

1
B3
B3
2
M4T OGGN -_420 AWG16 BK

3
B5
B5
4
M4S OGBK -_422 AWG16 BK

5
B4
B4
6
M4R GYRD
M4S GY
3
D11
D11
OGBU
DC-BUSBAR
M4T
D12
D12
D13
D13
-X13
M2R BU -_406 AWG16

1
M2R BNBK -_407 AWG16
A7
A7
2
M2T BNRD -_408 AWG16
A8
A8
3
M2T BNWH -_409 AWG16
A11
A11
4
M2S BNBU -_410 AWG16
A12
A12
5
M2S BNGN -_411 AWG16
A9
A9
6
A10
A10
4
-X14
M5R OGWH -_424 AWG16 BK

1
B6
B6
2
3
M5T PKGN -_425 AWG16 BK

4
B8
B8
M5S PKBK -_426 AWG16 BK

5
B7
B7
6
OGRD
Lab/Office:
M5R
M5S OG
D14
D14
M5T PKBU
D15
D15
D16
D16
5
-X15
M3R BN -_412 AWG16
IRB 4400
1
M3R GNRD -_413 AWG16

A13
A13
2
M3T GYBU -_414 AWG16

A14
A14
3
M3T GYGN -_415 AWG16

B1
B1
4
M3S GNWH -_416 AWG16

B2
B2
5
M3S GYBK -_417 AWG16

A15
A15
6
WHBU
A16
A16
WHGN
C13
C13
WHRD
SERVO DRIVE SYSTEM
C14
C14
C15
C15
-X16
6
M6R PKRD -_428 AWG16 BK

1
B9
B9
2
M6T PK -_430 AWG16 BK

3
B11
B11
4
M6S PKWH -_432 AWG16 BK

5
AWG10
B10
B10
6
AWG10
Status:
C3
7
C4
Document no.
Approved
C5
C6
2008-07-17
C7
C8
C9
C10
Plant:
C11
C12
Location:
3HAC024480-004
DRIVE MODULE
+ DM
8
03
= CAB
Sublocation: + 4400
Rev. Ind
MANIPULATOR
Total 153
Next 162
Page 161
1 2 3 4 5 6 7 8
=MAN+R1-SMB
-XS/XP2
/91.6 / MRCO1 SDI
/91.6 / 24V_SMB1 24V BOARD
F F
/91.6 / MRC_0V;2
G
/91.6 / MRC_0V;3 H 0V
J J BATSUP
K K BATLD
L L
KEYPIN
M
=MAN+R1-MP
-_433 -XS/XP1
/89.5 AWG16 WH
EXT. LAMP C16 C16

DRIVE MODULE /89.7 -_434 AWG16 BU VT
X40 BRAKEPB B16 B16

/89.6 -_435 AWG16 BU RDBK
BRAKEREL1 B12 B12

/89.6 -_436 AWG16 BU RDBU
BRAKEREL2 B13 B13
/88.7 -_438 AWG16 BU RDGN
/ OV BRAKE;4 B14 B14

CONTACTOR UNIT /88.7 -_439 AWG16 BU VTGN
A43-X5 / PTC1 C2 C2
/88.7 -_440 AWG16 BU VTBU
/ PTC1 ret C1 C1
/88.7 -_437 AWG16 BU VTWH
/ 0V BRAKE;3 B15 B15
/88.2 / A43-X21:2 LIM 1A -_441 AWG16 BU RD

D2 D2
CONTACTOR UNIT /88.2 / A43-X21:4 LIM 2A -_442 AWG16 BU RDWH
A43-X21 D1 D1
/88.2 / A43-X21:3 LIM 2B -_443 AWG16 BU VTBK
D3 D3
/88.2 / A43-X21:1 LIM 1B -_444 AWG16 BU VTRD
D4 D4

Sublocation: + 4400
IRB 4400
Next 163
1 2 3 4 5 6 7 8

Customer IRB 4400
-XS/XP5
Connection -XP/XT6
=MAN+R1-CP/CS
-W648 AWG18 OG CPA
1 -W649 AWG18 OG A1 A1 CPB
2 -W650 AWG18 OG B1 B1 CPC
3 -W651 AWG18 OG C1 C1 CPD
4 -W652 AWG18 OG D1 D1 CPE
5 -W653 AWG18 OG A2 A2 CPF
6 -W654 AWG18 OG B2 B2 CPJ
7 -W655 AWG18 OG C2 C2 CPK
8 -W656 AWG18 OG D2 D2 CPL
9 -W657 AWG18 OG A3 A3 CPM
10 -W658 AWG18 OG B3 B3
11 -W659 AWG18 OG C3 C3
12 D3 D3
-XP/XT5.1
-W625 AWG24 OG CSA

1 -W626 AWG24 OG B5 B5 CSB
2 -W627 AWG24 OG C5 C5 CSC
3 -W628 AWG24 OG D5 D5 CSD
4 -W629 AWG24 OG A6 A6 CSE
5 -W630 AWG24 OG B6 B6 CSF
6 -W631 AWG24 OG C6 C6 CSG
7 -W632 AWG24 OG D6 D6 CSH
8 -W633 AWG24 OG A7 A7 CSJ
9 -W634 AWG24 OG B7 B7 CSK
10 -W635 AWG24 OG C7 C7 CSL
11 -W636 AWG24 OG D7 D7 CSM
12 A8 A8
-XP/XT5.2
-W637 AWG24 OG CSN
13 -W638 AWG24 OG B8 B8 CSP
14 -W639 AWG24 OG C8 C8 CSR
15 -W640 AWG24 OG D8 D8 CSS
16 -W641 AWG24 OG A9 A9 CST
17 -W642 AWG24 OG B9 B9 CSU
18 -W643 AWG24 OG C9 C9 CSV
19 -W644 AWG24 OG D9 D9 CSW
20 -W645 AWG24 OG A10 A10 CSX
21 -W646 AWG24 OG B10 B10 CSY
22 -W647 AWG24 OG C10 C10 CSZ
23 D10
C10 D10

Sublocation: + 4400
DUAL CABINET
Next 164
1 2 3 4 5 6 7 8

Customer IRB 4400
-XS/XP5
Connection -XP/XT6
-709 =MAN+R1-CP/CS
1 1 AWG24 BK CPA
2 2 BN A1 A1 CPB
3 3 RD B1 B1 CPC
4 4 OG C1 C1 CPD
5 5 YE D1 D1 CPE
6 6 GN A2 A2 CPF
7 7 BU B2 B2 CPJ
8 8 VT C2 C2 CPK
9 9 GY D2 D2 CPL
10 10 WH A3 A3 CPM
11 11 WH/BK B3 B3
12 12 WH/BN C3 C3
D3 D3
-XP/XT5.1
-710
1 1 AWG24 BK CSA
2 2 BN B5 B5 CSB
3 3 RD C5 C5 CSC
4 4 OG D5 D5 CSD
5 5 YE A6 A6 CSE
6 6 GN B6 B6 CSF
7 7 BU C6 C6 CSG
8 8 VT D6 D6 CSH
9 9 GY A7 A7 CSJ
10 10 WH B7 B7 CSK
A8 A8
-XP/XT5.2
13 13 WH/RD CSN
21 21 BN/RD A10 A10 CSX
22 22 BN/OG B10 B10 CSY
23 23 BN/YE C10 C10 CSZ
D10
C10 D10

Sublocation: + 4400
SINGLE CABINET
Next 165
1 2 3 4 5 6 7 8
CONTROL MODULE
Connection IRB 4400
-XS/XP8
-XP/XT8 =MAN+R1-SW
-_601 AWG24 OG
1 A A
-_602 AWG24 OG
2 B B
-_603 AWG24 OG
3 C C
-_604
AWG24 OG
4 D D
-_605 AWG24 OG
5 E E
-_606 AWG24 OG
6 F F
-_607 AWG24 OG
7 J J
-_608 AWG24 OG
8 K K
-_609 AWG24 OG
9 L L
-_610 AWG24 OG
10 M M
-_611 AWG24 OG
11 G G
-_612 AWG24 OG
12 H H

Sublocation: + 4400
DUAL CABINET
Next 166
1 2 3 4 5 6 7 8
CONTROL MODULE
Connection IRB 4400
-XS/XP8
-XP/XT8 =MAN+R1-SW
-705
AWG24 BK
1 A A
BN
2 B B
RD
3 C C
OG
4 D D
YE
5 E E
GN
6 F F
BU
7 J J
VT
8 K K
GY
9 L L
WH
10 M M
WH/BK
11 G G
WH/BN
12 H H

Sublocation: + 4400
SINGLE CABINET
Next 170
1 2 3 4 5 6 7 8
IRB660 and IRB66xx-76xx cabinet module

Sublocation +6676

IRB 660 and IRB 66xx-76xx Approved
Sublocation: + 6676
CABINET MODULE
Next 171
-A41.1
Latest revision:
1
Prepared by, date:

=MAN+R1-MP
-XS/XP1
-X11
17 GNRD M1R -_400 AWG12 BK
17
17
27 OGGN M1R -_401 AWG12 BK
24
24
16 BN M1T -_402 AWG12 BK
19
19
26 OGBU M1T -_403 AWG12 BK
26
26
18 GNWH M1S -_404 AWG12 BK

5
18
18
25 OGBK M1S -_405 AWG12 BK
2
25
25
Approved by, date:

-X12
1 BKBU M4R -_418 AWG12 BK

1
1
1
DC-BUSBAR
3 BKRD M4T -_420 AWG12 BK

3
10
10
4
2 BKGN M4S -_422 AWG12 BK

5
2
2
6
3
-X13
23 GYWH M2R -_406 AWG12 BK

1
23
23
15 BNWH M2R -_407 AWG12 BK
2
32
32
24 GY M2T -_408 AWG12 BK
3
21
21
13 BNGN M2T -_409 AWG12 BK

4
30
30
22 GYRD M2S -_410 AWG12 BK

5
22
22
14 BNRD M2S -_411 AWG12 BK

6
4
31
31
-X14
20 GYBU M5R -_424 AWG12 BK

1
20
20
2
21 GYGN M5T -_425 AWG12 BK

3
Lab/Office:
29
29
4
19 GYBK M5S -_426 AWG12 BK

5
28
28
6
5
-X15
10 BU M3R -_412 AWG12 BK

1
3
3
4 BKWH M3R -_413 AWG12 BK

2
4
4
IRB 6600 - 7600

12 BNBU M3T -_414 AWG12 BK
3
7
7
5 BK M3T -_415 AWG12 BK

4
14
14
SERVO DRIVE SYSTEM 11 BNBK M3S -_416 AWG12 BK

5
5
5
6
6 BUBK M3S -_417 AWG12 BK

6
6
6
-X16
9 BUWH M6R -_428 AWG12 BK

1
9
9
2
7 BUGN M6T -_430 AWG12 BK

3
16
16
4
8 BURD M6S -_432 AWG12 BK

5
8
8
Status:
6
7
AWG10 GNYE
Document no.
Approved
AWG10 GNYE
Plant: 2008-07-17
Location:
3HAC024480-004
+ DM
8
03
= CAB
Sublocation: + 6676
Rev. Ind
MANIPULATOR
DRIVE MODULE
Total 153
Next 172
Page 171
1 2 3 4 5 6 7 8
DRIVE
MODULE MANIPULATOR
=MAN+R1-SMB
-XS/XP2
/91.6 / MRCO1 SDI
A A
/91.6 / MRCO1_N SDI-N
B B
/91.6 / MRCI1 SDO SERIAL
C C MEASUREMENT
AXIS COMPUTER BOARD /91.6 / MRCI1_N SDO-N BOARD
A42-X4 D D
/91.6 / MRC_0V;1 0V
E E
/91.6 / 24V_SMB1 24V
F F
/91.6 / MRC_0V;2 BAT BR
G G
BAT BR
H H
/91.6 / MRC_0V;3 0V
J J
BATSUP
K K
AWG16 BU 1 2 BU EXT.LAMP EXT.LAMP
AWG16 L L
-DP1
1
-C1
2
BU
AWG16
/89.5 -_433 AWG16 BU
EXT. LAMP =MAN+R1-MP

-_434 -XS/XP1
DRIVE MODULE /89.7 AWG16 BU 28 OGRD BRAKE PB
XP40 BRAKEPB 11 11
/89.6 -_435 AWG16 BU 30 OG BRAKE RELEASE
BRAKEREL1 13 13 BRAKE RELEASE
/89.6 -_436 AWG16 BU
BRAKEREL2
/88.7 -_437 AWG16 BU 29 OGWH 0V BRAKE

/ OV BRAKE;4 12 12 0V BRAKE
CONTACTOR UNIT /88.7 -_439 AWG16 BU 31 PKBK PTC
A43-X5 / PTC1 27 27
/88.7 -_440 AWG16 BU 32 PKWH 0V PTC
/ PTC1 ret 15 15
/88.7 -_438 AWG16 BU
/ 0V BRAKE;3

Sublocation: + 6676
IRB 6600 - 7600
Next 173
1 2 3 4 5 6 7 8
Customer CONTROL MANIPULATOR

Connection MODULE IRB 6600, 7600
-XS/XP8
-XP/XT8.1
-601 AWG24 OG
=MAN+R1-SW
1 A A
-602 AWG24 OG
2 B B
-603 AWG24 OG
3 C C
-604 AWG24 OG
4 D D
-605 AWG24 OG
5 E E
-606 AWG24 OG
6 F F
-607 AWG24 OG
7 G G
-608 AWG24 OG
8 H H
-609 AWG24 OG
9 J J
-610
AWG24 OG
10 K K
-611 AWG24 OG
11 L L
-612 AWG24 OG
12 M M
-XP/XT8.2
-613 AWG24 OG
13 N N
-614 AWG24 OG
14 P P
-615 AWG24 OG
15 R R
-616 AWG24 OG
16 S S
-617 AWG24 OG
17 T T
-618 AWG24 OG
18 U U
-619 AWG24 OG
19 V V
-620 AWG24 OG
20 W W
-621 AWG24 OG
21 X X
-622 AWG24 OG
22 Y Y
-623 AWG24 OG
23 Z Z
-624 AWG24 OG
24 a a

POSITION SWITCH 1 Approved
Sublocation: + 6676
DUAL CABINET
Next 174
Prepared by, date: Approved by, date: IRB 6600 - 7600 3HAC024480-004 03 Total 153
1 2 3 4 5 6 7 8

-XS/XP8
-XP/XT8.1
-706
AWG24 BK
=MAN+R1-SW
1 A A
BN
2 B B
RD
3 C C
OG
4 D D
YE
5 E E
GN
6 F F
BU
7 G G
VT
8 H H
GY
9 J J
WH
10 K K
WH/BK
11 L L
WH/BN
12 M M
-XP/XT8.2
WH/RD
13 N N
WH/OG
14 P P
WH/YE
15 R R
WH/GN
16 S S
WH/BU
17 T T
WH/VT
18 U U
WH/GY
19 V V
BN/BK
20 W W
BN/RD
21 X X
BN/OG
22 Y Y
BN/YE
23 Z Z
BN/GN
24 a a

POSITION SWITCH 1 Approved
Sublocation: + 6676
SINGLE CABINET
Next 175
1 2 3 4 5 6 7 8

-XS/XP58
AWG 24 OG
-XP/XT58.1
601 =MAN+R1-SW23
1 A A
602
2 B B
603
3 C C
604
4 D D
605
5 E E
606
6 F F
607
7 G G
608
8 H H
609
9 J J
610
10 K K
611
11 L L
612
12 M M
-XP/XT58.2
613
13 T T
614
14 U U
615
15 V V
616
16 W W
617
17 X X
618
18 Y Y
619
19 Z Z
620
20 a a
621
21 b b
622
22 c c
623
23 d d
624
24 e e

POSITION SWITCH 2/3 Approved
Sublocation: + 6676
DUAL CABINET
Next 176
1 2 3 4 5 6 7 8

-XS/XP58
-XP/XT58.1
-707
AWG24 BK
=MAN+R1-SW23
1 A A
BN
2 B B
RD
3 C C
OG
4 D D
YE
5 E E
GN
6 F F
BU
7 G G
VT
8 H H
GY
9 J J
WH
10 K K
WH/BK
11 L L
WH/BN
12 M M
-XP/XT58.2
WH/RD
13 T T
WH/OG
14 U U
WH/YE
15 V V
WH/GN
16 W W
WH/BU
17 X X
WH/VT
18 Y Y
WH/GY
19 Z Z
BN/BK
20 a a
BN/RD
21 b b
BN/OG
22 c c
BN/YE
23 d d
BN/GN
24 e e

POSITION SWITCH 2/3 Approved
Sublocation: + 6676
SINGLE CABINET
Next 177
1 2 3 4 5 6 7 8
OPTION: COOLING AXIS 1,2.
1)IF POS SW 2/3 AND COOLING 1,2. MANIPULATOR

1)
-BOX1
1) R1.XS.SW23 =MAN+R1-SW23
2)IF ONLY COOLING 1,2. -R1.XP.SW23
A A
B B
C C
D D
E E
F F
G G
H H
J J
K K
L L
M M
T T
U U
V V
W W
X X
Y Y
Z Z
a a
b b
c c
DRIVE d d
MODULE e e
Not in use
S S
Not in use
2) i i
1) 1) 2) R1.FAN.SW23 2)
-R1FAN.SW23
/88.8 / +24V COOL;4 AWG24 1/WH 24V COOL 24V FAN1
N N
0,23 1/BU
/88.8 / 0V COOL;4 0V COOL 0V FAN1
P P
/88.8 / FAN1 ret 3/WH FAN1 ret T1
R R
/88.8 / +24V COOL;5 2/WH 24V COOL 24V FAN2

f f
/88.8 / 0V COOL;5 2/OG 0V COOL 0V FAN2
g g
/88.8 / FAN2 ret 3/GN FAN2 ret T2
h h

POS.SWITCH 2/3 AND COOLING AXES 1/2 Approved
Sublocation: + 6676
DUAL CABINET
Next 178
1 2 3 4 5 6 7 8
CONTROL
MODULE MANIPULATOR
DRIVE
MODULE
-XS/XP58 =MAN+R1-SW23
/88.8 / +24V COOL;4 24V COOL 24V FAN1
N N
P P
/88.8 / FAN1 ret FAN1 ret T1
R R
Not in use
S
/88.8 / +24V COOL;5 24V COOL 24V FAN2

f f
g g
/88.8 / FAN2 ret FAN2 ret T2
h h
Not in use
i

COOLING AXES 1/2 Approved
Sublocation: + 6676
SINGLE CABINET
Next 179
1 2 3 4 5 6 7 8
Customer CONTROL MODULE MANIPULATOR

Connection IRB 6600-7600
-XP/XT6 -XS/XP13
=MAN+R1-CP/CS
-670 AWG18 CP4
1 A1 D1
-671 AWG18 CP5
2 A2 D6
-672 AWG18 CP6
3 A3 D3
-673 AWG18 CP7
4 A4 D4
-XP/XT5.1
-677 AWG24 CS
1 -678 AWG24 B1 B1 CS
2 -679 AWG24 B2 B2 CS
3 -680 AWG24 B11 B11 CS
4 -681 AWG24 B12 B12 CS
5 -682 AWG24 B13 B13 CS
6 -683 AWG24 B14 B14 CS
7 -684 AWG24 C19 C19 CS
8 -705 1/WH C21 C21 CS
9 AWG24 1/BU B7 B7 CS
10 2/WH B8 B8 CS
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -685 AWG24 B6 B6 CS
5 -686 AWG24 C16 C16 CS
6 -687 AWG24 C17 C17 CS
7 -688 AWG24 C18 C18 CS
8 -689 AWG24 C20 C20 CS
9 -690 AWG24 B22 B22 CS
10 -691 AWG24 B23 B23 CS
11 -692 AWG24 B24 B24 CS
12 B25 B25
-XP/XT5.3
-693 AWG24 CS
1 -694 AWG24 B15 B15 CS
2 -695 AWG24 B16 B16 CS
3 -696 AWG24 B18 B18 CS
4 -697 AWG24 B19 B19 CS
5 -698 AWG24 B20 B20 CS
6 -699 AWG24 B21 B21
7 -700 AWG24 C10
8 -666 AWG24 C11
9 -667 AWG24 C12
10 -668 AWG24 C13
11 -669 AWG24 C14
12 AWG16 C15
For more information aboute Option connected to XS13.
SPOTPACK circuit diagram 3HAC026208-001
DRESSPACK circuit diagram 3HAC026209-001

Sublocation: + 6676
DUAL CABINET
Next 180
1 2 3 4 5 6 7 8

-XP/XT6 -713 -XS/XP13
AWG20 BK
=MAN+R1-CP/CS
1 1 A1 A1 CP4
BN A1 D1
1
2 2 RD A2 A2 CP5
OG A2 D6
2
3 3 YE A3 A3 CP6
GN A3 D3
3
4 4 BU A4 A4 CP7
VT A4 D4
4
-XP/XT5.1 -711
AWG24 BK CS
1 BN B1 B1 CS
2 RD B2 B2 CS
3 OG B11 B11 CS
4 YE B12 B12 CS
5 GN B13 B13 CS
6 BU B14 B14 CS
7 VT C19 C19 CS
8 -712 1/WH C21 C21 CS
10 2/WH B8 B8 CS
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -711 GY B6 B6 CS
5 AWG24 WH C16 C16 CS
6 WH/BK C17 C17 CS
7 WH/BN C18 C18 CS
8 WH/RD C20 C20 CS
9 WH/OG B22 B22 CS
10 WH/YE B23 B23 CS
11 WH/GN B24 B24 CS
12 B25 B25
-XP/XT5.3
-713
AWG20 GY CS
1 WH B15 B15 CS
2 WH/BK B16 B16 CS
3 WH/BN B18 B18 CS
4 WH/RD B19 B19 CS
5 WH/OG B20 B20 CS
6 WH/YE B21 B21
7 WH/GN C10
8 WH/BU C11
9 WH/VT C12
10 WH/GY C13
11 BN/BK C14
12 AWG16 C15


Sublocation: + 6676
SINGLE CABINET
Next 181
1 2 3 4 5 6 7 8

IRB 6600-7600
Customer
Connection
-A35
-X2 =MAN+R1-CP/CS
-707
-XS/XP13
2/BK V- 0V
OPTION : DEVICENET 1 F2 B23
1/BU CAN_L CAN_L
2 F4 A4
Bare wire SHIELD
3
1/WH CAN_H CAN_H
4 F3 A3
2/RD V+ +24V CAN
5 F1 B22
-A37
-708
AWG24 =MAN+R1-CP/CS
-X5 2/GY
-XS/XP13
DO DO
1 3/BN DO_N F7 A9 DO_N
6 1/YE DI F8 A10 DI
OPTION : INTERBUS 2 2/PK DI_N F9 A11 DI_N
7 1/GN GND F10 A12 GND
3 3/WH GND F1 B22
-A33
-XS/XP13 =MAN+R1-CP/CS
-709
-DP-M1 0,34 1/RD
RXD/TXD-P RXD/TXD-P
OPTION : PROFIBUS 1B F5 A5
1/GN RXD/TXD-N RXD/TXD-N
1A F6 A6

DevNet//IBUS//PBUS ADDITION TO CP/CS Approved
Sublocation: + 6676
IRB 6600 - 7600
Next 182
1 2 3 4 5 6 7 8

Connection -XS/XP13 IRB 6600-7600
-XP/XT6
=MAN+R1-CP/CS
-670 AWG18 CP4
1 A1 D1
-671 AWG18 CP5
2 A2 D6
-672 AWG18 CP6
3 A3 D3
-673 AWG18 CP7
4 A4 D4
-XP/XT5.1
-677 AWG24 CS
1 -678 AWG24 B1 B1 CS
2 -679 AWG24 B2 B2 CS
3 -680 AWG24 B11 B11 CS
4 -681 AWG24 B12 B12 CS
5 -682 AWG24 B13 B13 CS
6 -683 AWG24 B14 B14 CS
7 -684 AWG24 C19 C19 CS
8 -705 1/WH C21 C21 CS
10 2/WH B8 B8 CS
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -685 AWG24 B6 B6 CS
5 -686 AWG24 C16 C16 CS
6 -687 AWG24 C17 C17 CS
7 -688 AWG24 C18 C18 CS
8 -689 AWG24 C20 C20 CS
9 -690 AWG24 B22 B22 CS
10 -691 AWG24 B23 B23 CS
11 -692 AWG24 B24 B24 CS
12 B25 B25
-XP/XT5.3
-693 AWG24 CS
1 -694 AWG24 B15 B15 CS
2 -695 AWG24 B16 B16 CS
3 -696 AWG24 B18 B18 CS
4 -697 AWG24 B19 B19 CS
5 -698 AWG24 B20 B20 CS
6 -699 AWG24 B21 B21 CS
7 -700 AWG24 C10 A3 CS
8 -666 AWG24 C11 A4 CS
9 -667 AWG24 C12 A9 CS
10 -668 AWG24 C13 A10 CS
11 -669 AWG24 C14 A11 CS
12 AWG16 C15 A12
OPTION //PROFIBUS acc. to page 181

Sublocation: + 6676_P
DUAL CABINET PROFIBUS
Next 183
1 2 3 4 5 6 7 8

-XP/XT6
=MAN+R1-CP/CS
-670 AWG18 CP4
1 A1 D1
-671 AWG18 CP5
2 A2 D6
-672 AWG18 CP6
3 A3 D3
-673 AWG18 CP7
4 A4 D4
-XP/XT5.1
-677 AWG24 CS
1 -678 AWG24 B1 B1 CS
2 -679 AWG24 B2 B2 CS
3 -680 AWG24 B11 B11 CS
4 -681 AWG24 B12 B12 CS
5 -682 AWG24 B13 B13 CS
6 -683 AWG24 B14 B14 CS
7 -684 AWG24 C19 C19 CS
8 -705 1/WH C21 C21 CS
10 2/WH B8 B8 CS
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -685 AWG24 B6 B6 CS
5 -686 AWG24 C16 C16 CS
6 -687 AWG24 C17 C17 CS
7 -688 AWG24 C18 C18 CS
8 -689 AWG24 C20 C20
9 -690 AWG24 B22 CS
10 -691 AWG24 B23 B23 CS
11 -692 AWG24 B24 B24 CS
12 B25 B25
-XP/XT5.3
-693 AWG24 CS
1 -694 AWG24 B15 B15 CS
2 -695 AWG24 B16 B16 CS
3 -696 AWG24 B18 B18 CS
4 -697 AWG24 B19 B19 CS
5 -698 AWG24 B20 B20 CS
6 -699 AWG24 B21 B21 CS
7 -700 AWG24 C10 A5 CS
8 -666 AWG24 C11 A6 CS
9 -667 AWG24 C12 A3 CS
10 -668 AWG24 C13 A4
11 -669 AWG24 C14
12 AWG16 C15 For more information aboute Option connected to XS13.
OPTION //INTERBUS-S acc. to page 181 SPOTPACK circuit diagram 3HAC026208-001

Sublocation: + 6676_I
DUAL CABINET INTERBUS
Next 184
1 2 3 4 5 6 7 8

-XP/XT6
=MAN+R1-CP/CS
-670 AWG18 CP4
1 A1 D1
-671 AWG18 CP5
2 A2 D6
-672 AWG18 CP6
3 A3 D3
-673 AWG18 CP7
4 A4 D4
-XP/XT5.1
-677 AWG24 CS
1 -678 AWG24 B1 B1 CS
2 -679 AWG24 B2 B2 CS
3 -680 AWG24 B11 B11 CS
4 -681 AWG24 B12 B12 CS
5 -682 AWG24 B13 B13 CS
6 -683 AWG24 B14 B14 CS
7 -684 AWG24 C19 C19 CS
8 -705 1/WH C21 C21 CS
10 2/WH B8 B8 CS
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -685 AWG24 B6 B6 CS
5 -686 AWG24 C16 C16 CS
6 -687 AWG24 C17 C17 CS
7 -688 AWG24 C18 C18 CS
8 -689 AWG24 C20 C20
9 -690 AWG24 B22
10 -691 AWG24 B23 CS
11 -692 AWG24 B24 B24 CS
12 B25 B25
-XP/XT5.3
-693 AWG24 CS
1 -694 AWG24 B15 B15 CS
2 -695 AWG24 B16 B16 CS
3 -696 AWG24 B18 B18 CS
4 -697 AWG24 B19 B19 CS
5 -698 AWG24 B20 B20 CS
6 -699 AWG24 B21 B21 CS
7 -700 AWG24 C10 A5 CS
8 -666 AWG24 C11 A6 CS
9 -667 AWG24 C12 A9 CS
10 -668 AWG24 C13 A10 CS
11 -669 AWG24 C14 A11 CS
12 AWG16 C15 A12
OPTION //DEVICENET acc. to page 181 SPOTPACK circuit diagram 3HAC026208-001

Sublocation: + 6676_D
DUAL CABINET DEVICE NET
Next 185
1 2 3 4 5 6 7 8

Connection -XP/XT6 IRB 6600-7600
-713 -XS/XP13
AWG20 BK
=MAN+R1-CP/CS
1 1 A1 A1 CP4
BN A1 D1
1
2 2 RD A2 A2 CP5
OG A2 D6
2
3 3 YE A3 A3 CP6
GN A3 D3
3
4 4 BU A4 A4 CP7
VT A4 D4
4
-XP/XT5.1 -711
AWG24 BK CS
1 BN B1 B1 CS
2 RD B2 B2 CS
3 OG B11 B11 CS
4 YE B12 B12 CS
5 GN B13 B13 CS
6 BU B14 B14 CS
7 VT C19 C19 CS
8 -712 1/WH C21 C21 CS
10 2/WH B8 B8 CS
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -711 GY B6 B6 CS
6 WH/BK C17 C17 CS
7 WH/BN C18 C18 CS
8 WH/RD C20 C20 CS
9 WH/OG B22 B22 CS
10 WH/YE B23 B23 CS
11 WH/GN B24 B24 CS
12 B25 B25
-XP/XT5.3 -713
AWG20 GY CS
1 WH B15 B15 CS
2 WH/BK B16 B16 CS
3 WH/BN B18 B18 CS
4 WH/RD B19 B19 CS
5 WH/OG B20 B20 CS
6 WH/YE B21 B21 CS
7 WH/GN C10 A3 CS
8 WH/BU C11 A4 CS
9 WH/VT C12 A9 CS
10 WH/GY C13 A10 CS
11 BN/BK C14 A11 CS
12 AWG16 C15 A12
OPTION //PROFIBUS acc. to page 181 SPOTPACK circuit diagram 3HAC026208-001

Sublocation: + 6676_P
SINGLE CABINET PROFI BUS
Next 186
1 2 3 4 5 6 7 8

-XP/XT6 -713 -XS/XP13
AWG20 BK
=MAN+R1-CP/CS
1 1 A1 A1 CP4
BN A1 D1
1
2 2 RD A2 A2 CP5
OG A2 D6
2
3 3 YE A3 A3 CP6
GN A3 D3
3
4 4 BU A4 A4 CP7
VT A4 D4
4
-XP/XT5.1 -711
AWG24 BK CS
1 BN B1 B1 CS
2 RD B2 B2 CS
3 OG B11 B11 CS
4 YE B12 B12 CS
5 GN B13 B13 CS
6 BU B14 B14 CS
7 VT C19 C19 CS
8 -712 1/WH C21 C21 CS
10 2/WH B8 B8 CS
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -711 GY B6 B6 CS
6 WH/BK C17 C17 CS
7 WH/BN C18 C18 CS
8 WH/RD C20 C20
9 WH/OG B22 CS
10 WH/YE B23 B23 CS
11 WH/GN B24 B24 CS
12 B25 B25
-XP/XT5.3
-713
AWG20 GY CS
1 WH B15 B15 CS
2 WH/BK B16 B16 CS
3 WH/BN B18 B18 CS
4 WH/RD B19 B19 CS
5 WH/OG B20 B20 CS
6 WH/YE B21 B21 CS
7 WH/GN C10 A5 CS
8 WH/BU C11 A6 CS
9 WH/VT C12 A3 CS
10 WH/GY C13 A4
11 BN/BK C14
AWG16
12 C15
OPTION //INTERBUS-S acc. to page 181

Sublocation: + 6676_I
SINGLE CABINET INTERBUS
Next 187
1 2 3 4 5 6 7 8

-XP/XT6 -713 -XS/XP13
AWG20 BK
=MAN+R1-CP/CS
1 1 A1 A1 CP4
BN A1 D1
1
2 2 RD A2 A2 CP5
OG A2 D6
2
3 3 YE A3 A3 CP6
GN A3 D3
3
4 4 BU A4 A4 CP7
VT A4 D4
4
-XP/XT5.1 -711
AWG24 BK CS
1 BN B1 B1 CS
2 RD B2 B2 CS
3 OG B11 B11 CS
4 YE B12 B12 CS
5 GN B13 B13 CS
6 BU B14 B14 CS
7 VT C19 C19 CS
8 -712 1/WH C21 C21 CS
10 2/WH B8 B8 CS
11 2/OG B9 B9 CS
12 B10 B10
-XP/XT5.2
3/WH CS
1 3/GN B3 B3 CS
2 4/WH B4 B4 CS
3 4/BN B5 B5 CS
4 -711 GY B6 B6 CS
6 WH/BK C17 C17 CS
7 WH/BN C18 C18 CS
8 WH/RD C20 C20
9 WH/OG B22
10 WH/YE B23 CS
11 WH/GN B24 B24 CS
12 B25 B25
-XP/XT5.3 -713
AWG20 GY CS
1 WH B15 B15 CS
2 WH/BK B16 B16 CS
3 WH/BN B18 B18 CS
4 WH/RD B19 B19 CS
5 WH/OG B20 B20 CS
6 WH/YE B21 B21 CS
7 WH/GN C10 A5 CS
8 WH/BU C11 A6 CS
9 WH/VT C12 A9 CS
10 WH/GY C13 A10 CS
11 BN/BK C14 A11 CS
12 AWG16 C15 A12
OPTION //DEVICENET acc. to page 181 SPOTPACK circuit diagram 3HAC026208-001

Sublocation: + 6676_D
SINGLE CABINET DEVICE NET
Next 200
1 2 3 4 5 6 7 8
IRB6400R cabinet module

Sublocation +6400R

IRB 6400R CABINET MODULE Approved
Sublocation: + 6400R
Next 201
1 2 3 4 5 6 7 8
DC-BUSBAR

-A41.1
-X11 1 2 3 4 5 6 -X12 1 2 3 4 5 6 -X13 1 2 3 4 5 6 -X14 1 2 3 4 5 6 -X15 1 2 3 4 5 6 -X16 1 2 3 4 5 6

M1R
M1R
M4R
M4R
M2R
M2R
M5R
M5R
M3R
M3R
M6R
M1S
M1S
M4S
M4S
M2S
M2S
M5S
M5S
M3S
M3S
M6S
M1T
M1T
M4T
M4T
M2T
M2T
M5T
M5T
M3T
M3T
M6T
-XS/XP1 A1 A14 A2 B15 B1 A15 C13 C8 D13 D8 C14 D7 A4 A11 A5 B11 B4 A12 C3 C15 B3 D15 C4 D16 C11 A9 D12 B10 D11 B9 B6 B7 A7 DRIVE MODULE
BN//WH
OG/WH
GN/WH
OG/GN
BU/WH
BK/WH
OG/RD
PK/WH
OG/BU
GY/GN
GN/RD
BN/GN
BU/GN
BK/GN
BN/RD
PK/GN
GY/BU
BU/RD
BK/RD
BN/BU
PK/RD
GY/BK
BK/BU
BU/BK
BN/BK
PK/BU
PK/BK
PK/BK
OG
BU
BN
BK
PK
MANIPULATOR
=MAN+R1-MP 8 22 21 35 9 23 51 53 64 66 63 65 13 49 2 62 1 61 68 70 57 59 69 71 15 17 4 6 3 5 42 31 43

SERVO DRIVE SYSTEM Approved
IRB 6400R
Next 202
1 2 3 4 5 6 7 8
-XS/XP2 =MAN+R1-SMB
/91.6 / MRCO1 SDI
A 1
/91.6 / MRCO1_N SDI-N
B 2
/91.6 / MRCI1 SDO
C 3 SERIAL
AXIS COMPUTER BOARD /91.6 / MRCI1_N SDO-N MEASUREMENT
A42-X4 D 4
BOARD
/91.6 / MRC_0V;1 0V
E 5
/91.6 / 24V_SMB1 24V
F 6
/91.6 / MRC_0V;2 BAT BR
G 7
BAT BR
H 8
/91.6 / MRC_0V;3 0V
J 9
BATSUP
K 10
EXT LAMP
L 11
-XS/XP1 =MAN+R1-MP
/89.5 -433 AWG16 BU VTBK
DRIVE MODULE EXT. LAMP D1 52
XP40 /89.7 -434 AWG16 BU RDWH

BRAKEPB C12 11
/89.6 -435 AWG16 BU GYRD
BRAKEREL1 B12 36
/89.6 -436 AWG16 BU GYWH
BRAKEREL2 C9 48
/88.7 -438 AWG16 BU OGBK

/ OV BRAKE;4 D9 24
/88.7 -439 AWG16 BU RDGN
CONTACTOR UNIT / PTC1 C2 20
A43-X5 /88.7 -440 AWG16 BU RDBU

/ PTC1 ret C1 30
/88.7 -437 AWG16 BU GY
/ 0V BRAKE;3 B13 12

IRB 6400R
Next 203
1 2 3 4 5 6 7 8
CONTROL MODULE
MANIPULATOR
AWG24 AWG24
-XP/XT8.1 -XS8 =MAN+R1-SW
1/WH 1/WH
1 A A
1/BU 1/BU
2 B B
2/WH 2/WH
3 C C
2/OG 2/OG
4 D D
3/WH 3/WH
5 E E
3/GN 3/GN
6 F F
4/WH 4/WH
7 G G
4/BN 4/BN
8 H H
5/WH 5/WH
9 J J
5/GY 5/GY
10 K K
6/RD 6/RD
11 L L
6/BU 6/BU
12 M M
-XP/XT8.2
7/RD 7/RD
13 N N
7/OG 7/OG
14 P P
8/RD 8/RD
15 R R
8/GN 8/GN
16 S S
9/RD 9/RD
17 T T
9/BN 9/BN
18 U U
10/RD 10/RD
19 V V
10/GY 10/GY
20 W W
11/BK 11/BK
21 X X
22
23
24

POSITON SWITCH Approved
IRB 6400R
Next 204
1 2 3 4 5 6 7 8
=MAN+R1-CP/CS
-XP/XT6
1, BK
1 A1
2, BK 3-POL
2 A2
GNYE
A3
-XP/XT5.1
AWG24 1/WH CSA
1 1
1/BU CSB
2 2
2/WH CSC
3 3
2/OG CSD
4 4
3/WH CSE
5 5 25-POL
3/GN CSF
6 6
4/WH CSG
7 7
4/BN CSH
8 8
5/WH CSJ
9 9
5/GY CSK
10 10
-XS6
2/RD +24V
5 1
2/BK 0V
Connect to A35.X2 1 2 9-POL
1/WH CAN1_H
4 5
1/BU CAN1_L
2 9

CUSTOMER POWER/SIGNAL/BUS Approved
IRB 6400R
Next
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.
Except as may be expressly stated anywhere in this document, 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 document.
This document and parts thereof must not be reproduced or copied without ABB's written permission,
and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.
Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB at its then current charge.
© Copyright 2004 ABB ALL right reserved.
ABB Automation Technologies AB

Robotics
Sweden
Latest revision: Lab/Office: Status: Plant: = EUROMAP

EUROMAP 67 2008-07-17
+ CONTROLER
Location:
EUROMAP 12/SPI Approved Sublocation: +
COPYRIGHT page Document no. Rev. Ind Page 1
Next 2
Customer : EUROMAP 67
Control cabinet : EUROMAP 12/SPI
Drawing number :
Drawing version :
Manufacture :
Type :
Type of installation :
Control cabinet :
Mains voltage :
Supply :
Control voltage :
Year of construction : RCM
Project start :
Project manager :
Last revision :
Designed by : sejesun
Designed date : 2008-07-16
Number of pages :
:

EUROMAP 67 2008-07-17
+ CONTROLER
Location:
TITLE PAGE Document no. Rev. Ind Page 2
Next 3
Revison information 02
Sh.13 Connection changed at XT31
Sh 24-29 Changed new computer.
Sh.39 Added connections.
Sh.40 Added connections.
Sh.49 Added contact I/O1.X1 and I/O1.X2
Sh.50 Added contact I/O.X3
Revison information 03
Sh 14.1 added for e stop with 2 IMM.
Sh 51 and 52 added for 2 IMM
Sh 49 connection om I/O1.X1 changed and I/O1.X2 deleted.
Sh 40 Connections changed.

EUROMAP 67 2008-07-17
+ CM.1
Location:
REVISION INFORMATION Document no. Rev. Ind Page 3
Next 5
Prepared by, date: Approved by, date: Graphics 3HAC024120-004 03 Total 48
EUROMAP CONTROLER 1 COPYRIGHT page Approved 2008-04-01 sejesun
EUROMAP CONTROLER 2 TITLE PAGE Approved 2008-04-01 sejesun
EUROMAP CM.1 3 REVISION INFORMATION Approved 2008-04-01 sejesun
EUROMAP CM 5 Table of contents: (1 - 34) Approved 2008-07-16 sejesun
EUROMAP CM 6 Table of contents: (35 - 50) Approved 2008-04-01 sejesun
EUROMAP CM.1 8 CONVERTOR BOX HOUSING OVERVIEW Approved 2008-04-01 sejesun
EUROMAP CM 9 MAINS CONNECTION Approved 2008-04-01 sejesun
EUROMAP CM 11 MAINS CONNECTION Approved 2008-04-01 sejesun
EUROMAP CM 12 POWER SUPPLY Approved 2008-04-01 sejesun
EUROMAP CM 13 OPTION: POWER SUPPLY Approved 2008-04-01 sejesun
EUROMAP CM 14 EMERGENCY STOP Approved 2008-04-01 sejesun
EUROMAP2 CM 14.1 EMERGENCY STOPFOR 2 IMM Approved 2008-07-16 sejesun
EUROMAP CM.1 15 RUN CHAIN OPERATING MODE SELECTOR, 3 MODES Approved 2008-04-01 sejesun
EUROMAP CM.2 16 EMERGENCY STOP Approved 2008-07-16 sejesun
EUROMAP CM.3 17 RUN CHAIN Approved 2008-04-01 sejesun
EUROMAP CM.4 18 RUN CHAIN OPERATING MODE SELECTOR, 2 MODES Approved 2008-04-01 sejesun
EUROMAP CM.5 19 RUN CHAIN EXT OPERATING MODE SELECTOR, 2 MODES Approved 2008-04-01 sejesun
EUROMAP CM.6 20 RUN CHAIN EXT OPERATING MODE SELECTOR, 3 MODES Approved 2008-04-01 sejesun
EUROMAP CM 21 FPU, FLEXPENDANT Approved 2008-04-01 sejesun
EUROMAP CM.7 22 OPTION: EXTERNAL CONNECTIONSYSTEM SIGNALS Approved 2008-04-01 sejesun
EUROMAP CM 24 MAIN COMPUTER DSQC 639 Approved 2008-04-01 sejesun
EUROMAP CM 25 MAIN COMPUTER DSQC 639 Approved 2008-04-01 sejesun
EUROMAP CM 26 MAIN COMPUTER AC/BD Approved 2008-04-01 sejesun
EUROMAP CM 29 MAIN COMPUTER AC/BD ROBOT COMM. CARD DSQC 602 Approved 2008-04-01 sejesun
EUROMAP CM 30 PROFIBUS DP M/S Approved 2008-04-01 sejesun
EUROMAP CM.1 31 INTERBUS M/S Approved 2008-04-01 sejesun
EUROMAP CM 32 DEVICENET ADAPTER Approved 2008-04-01 sejesun
EUROMAP CM 33 DEVICENET ADAPTER Approved 2008-04-01 sejesun

EUROMAP 67 2008-07-17
+ CM
Location:
Next 6
EUROMAP CM 34 DUAL RS232 CARD Approved 2008-04-01 sejesun
EUROMAP CM 35 ETHERNET CARD Approved 2008-04-01 sejesun
EUROMAP CM 36 DIGITAL PART OF COMBI I/O ANDDIGITAL I/O UNIT Approved 2008-04-01 sejesun
EUROMAP CM.1 37 DIGITAL I/O UNIT Approved 2008-04-01 sejesun
EUROMAP CM.2 38 COMBI I/O UNIT Approved 2008-04-01 sejesun
EUROMAP CM.1 39 RELAY I/O UNIT Approved 2008-04-01 sejesun
EUROMAP CM.2 40 RELAY I/O UNIT Approved 2008-07-15 sejesun
EUROMAP CM.2 42 ANALOGUE I/O UNIT Approved 2008-04-01 sejesun
EUROMAP CM.2 43 REMOTE I/O UNIT Approved 2008-04-01 sejesun
EUROMAP CM 44 INTERBUS SLAVE Approved 2008-04-01 sejesun
EUROMAP CM 45 PROFIBUS DP SLAVE Approved 2008-04-01 sejesun
EUROMAP CM 46 ENCODER UNIT Approved 2008-04-01 sejesun
EUROMAP CM 47 XS13 Approved 2008-04-01 sejesun
EUROMAP CM 48 XS13Z Approved 2008-04-01 sejesun
EUROMAP CB 49 CONVERTER BOX EUROMAP 67/12 Approved 2008-07-15 sejesun
EUROMAP CB 50 CONVERTOR BOXEUROMAP 67/12 Approved 2008-04-01 sejesun

EUROMAP2 CB 51 EUROMAP 67FOR 2 IMM Approved 2008-07-16 sejesun
EUROMAP2 CB 52 EUROMAP 67 FOR 2 IMM Approved 2008-07-16 sejesun

EUROMAP 67 2008-07-17
+ CM
Location:
Next 8
1 2 3 4 5 6 7 8
HOUSING ON HOUSING ON HOUSING ON

CONVERTER BOX CONVERTER BOX IRC5 CABINET
PE PE
C A 1 1 C A 1 1
9 1 17 25
2 2
B 2 B 2
10 2 18 26
3
SOCKET 3
3 3
11 3 19 27
4 4
4 PIN 4
12 4 20 28
5 5
5 5
13 5 21 29
6 6
6 6
14 6 22 30
7 7
7 7
15 7 23 31
8 8
8 B 8 B
16 8 24 32
9 9
9 A C 9 A C
-XS13 -XS13Z -XS.13Z- -XS.13-

SOCKET PIN Z SOCKET Z
-16
1- 1-
-25 W_XS13 1-
-25
CONVERTER
64x1 mm2
BOX
17-
-32 -25
1- 1-
-25
PIN SOCKET PIN
EUROMAP 12/SPI EUROMAP 67
Latest revision: Lab/Office: Status: 2008-07-17 Plant: = EUROMAP

Location: + CM.1
CONVERTOR BOX Approved
Sublocation: +
HOUSING OVERVIEW
Next 9
Prepared by, date: JSUNDIN Approved by, date: MTORNROS 3HAC024120-004 03 Total 48
1 2 3 4 5 6 7 8
Control Module
Customer Manipulator
Connection IRB 1400
-XS/XP8 =EUROMAP
MAN 67-R1.SW
-XP/XT8
1)
/47.3 /49.3 /51.1 /51.5 / XT8:1 601 OG
1 A A
602 OG
1) 2 B B
/47.5 /49.6 /51.4 /51.7 / XT8:3 603 OG
3 C C
604 OG
4 D D
605 OG
5 E E
606 OG
6 F F
607 OG
7 J J
608 OG
8 K K
609 OG
10 L L
610 OG
9 M M
611 OG
11 G G
612 OG
12 H H
1) Alt. connected to a terminal block

Location: + CM
MAINS CONNECTION Approved
Sublocation: +
Next 11
Latest revision:
1
Prepared by, date:

XT16
JSUNDIN
/12.3 / 230V AC1;1 -152 AWG16 BK
L1
/13.2 / 230V AC1;1
2
L1
/12.1 / 230V AC1;3
L1
Approved by, date:

/13.5 / 230V AC1;1
L1
MAIN SWITCH
JUMPER
/13.7 / 230V AC1;1
-Q2
L1
-173 AWG16 BK 154 AWG16 BK
L1
T1
L1
MTORNROS
-174 AWG16 BK 155 AWG16 BK
L2
T2
L2
/12.3 / 230V AC2;1 -153 AWG16 BK
L3
T3
L2
3
/13.5 / 230V AC2;1
/12.1 / 230V AC2;3 L2

L2
230V AC1_DM
JUMPER
230V AC2_DM
/13.2 / 230V AC2;1

L2
/13.7 / 230V AC2;1

L2
4
Lab/Office:
5
-F2
MAINS CONNECTION
6
230V AC1_DC
1
2
T1.X2:230V
230V AC2_DC
3
4
TRANSFORMER UNIT
-E1
Status:
7
Document no.
Approved
Plant: 2008-07-17
Location:
3HAC024120-004
Sublocation: +
+ CM
8
03
= EUROMAP
Total 48
Next 12
Rev. Ind Page 11
Latest revision:
1
-G2
Prepared by, date:

230V AC1;3 / /11.2
JSUNDIN
230V AC2;3 / /11.3
-X2
AWG18 BU
FOR SINGLE CABINET
/14.2 / 24V SYS -250
1
/14.2 / 0V SYS -251 AWG18 BU
2
2
/14.2 / 24V COOL -252 AWG18 BU
PANEL BOARD
24V COOL
24V SYS
/14.2 / 0V COOL -253 AWG18 BU
Approved by, date:

-X1
230V AC1;1 / /11.2

1
AWG16 BK
MTORNROS
-153 230V AC2;1 / /11.3
5
AC -INPUT
3
FOR DUAL CABINET
-X3
/24.2 / 24V PC -301 AWG18
3
1
/24.2 / 24V PC -302 AWG18
AWG16 gnye
UNIT
AWG18
24V PC
/24.2 / 0V PC -303
COMPUTER
3
/24.2 / 0V PC -304 AWG18
4
4
-G3
-X1
-X4
+
1
1
+
2
2
NC
Lab/Office:
3
3
NC
4
4
+
5
5
5
ULTRA CAP
6
6
-
7
7
ULTRA CAP
8
8
+Sense
POWER SUPPLY
9
9
NC
-
10
10
6
-X5
/25.6 / USB2 +5V AWG24 RD

1
/25.6 / USB2 D- AWG28 WH

2
MAIN
USB
/25.6 / USB2 D+ AWG28 GN

3
COMPUTER
Status:
/25.6 / USB2_GND AWG24 BK

7
Document no.
Approved
Plant: 2008-07-17
Location:
3HAC024120-004
Sublocation: +
+ CM
8
03
= EUROMAP
Total 48
Next 13
Rev. Ind Page 12
-G6
Latest revision:
1
Prepared by, date:

DEVICENET
POWER SUPPLY
JSUNDIN
-X2
-X1
/33.1 / +24V devicenet -308 AWG16 230V AC1;1 / /11.2
AC
L
+
-309 AWG16 230V AC2;1 / /11.3
DC
-
N
2
+
/33.1 / 0V devicenet
Approved by, date:

/36.1 / +24V devicenet AWG16
gnye
GND
MTORNROS
/39.2 / +24V devicenet
3



4


.5
-G4
Lab/Office:
POWER
SUPPLY
CUSTOMER
.5
5
-XT31
-X2
-X1
/48.4 /50.4 /52.2 /52.6 / XT31 :2 1032 230V AC1;1 / /11.2

1
2
AC
24
AC
/48.6 /50.6 /52.4 /52.8 / XT31 :4 1046 230V AC2;1 / /11.3

5
6
DC
0
AC
/36.8 /39.7 / 0VDC:IMM 1055

GND
Customer
24
OPTION: POWER SUPPLY

Connection
6
0
.7
-G5
POWER
SUPPLY
CUSTOMER
.6
Status:
-X2
-X1
24V I/O 230V AC1;1 / /11.2

7
AC
24
AC
Document no.
Approved
0V I/O 230V AC2;1 / /11.4

DC
0
AC
2008-07-17
Customer
GND
Connection
Plant:
24V I/O
Location:
3HAC024120-004
24
0V I/O
Sublocation: +
0
+ CM
8
03
= EUROMAP
Total 48
Next 14
Rev. Ind Page 13
1 2 3 4 5 6 7 8
PANEL BOARD
-A21
.5
.5
-250 -X12 24V FPU POWER

/12.2 / 24V SYS AWG18 BU 24V SYS
1 24V PANEL
/12.2 / 0V SYS -251 AWG18 BU 0V SYS
2
24V PANEL
/12.2 / 24V COOL -252 AWG18 BU
3
/12.2 / 0V COOL -253 AWG18 BU
4
/49.2 / NA1.1:IRB
EMP12/SPI /49.3 / NA2.1:IRB
X10
-X1 -X2 -209
/47.2 / NA1.1:IRB 1000 ES1 top 209 AWG20 ES FPU 1:A / /21.2
EMP67 -211
/47.3 / NA2.1:IRB 1001 ES2 top 3 5 AWG20 ES FPU 2:A / /21.2 FPU
-212 AWG20 ES FPU 2:B / /21.2
JUMPER
3 7
8 -210 AWG20 ES FPU 1:B / /21.2
/48.3 /50.3 / KN1:23 1040 0V 0V 6
/48.2 /50.2 / KN1:13 1025 24V Panel 4 24V PANEL
4
RunCh+
RunCh+
Run CH1 top

X9 -S21.3
5
EMERGENCY ES1OUT:A -237 AWG20 21 22
STOP OUTPUT 1 ES2 OUT:A 1 17 -238 AWG20

1 18 -233 AWG20 11 12
EMERGENCY ES2 OUT:B 13 -234 AWG20
STOP OUTPUT 2 ES1OUT:B 2 14 -231 AWG20
2 11 -232 AWG20
/47.5 / NA2.2:IRB 1018 Sep ES2:A RunCh+ 12 -235 AWG20
EMP67 RunCh+ -236
/47.5 / NA1.2:IRB 1017 Sep ES1:A 9 15 AWG20
9 -ES2 16
-ES1
/49.5 / NA2.2:IRB
EMP12/SPI
/49.5 / NA1.2:IRB
U U
/48.5 /50.3 / KN1:14 1042 Sep ES1:B A2 A1

10
/48.5 /50.3 / KN1:24 1041 Sep ES2:B A1 A2
10
ES2 bottom
JUMPER
JUMPER
7
-X11
SUPPLY 0V 7
24V Panel 8 1
8 2 24V_Sig.ref. / /24.7
SOFT_ESO
24V PANEL 3 RS485+ / /24.7
SOFT_ESI 4 RS485- / /24.7 MAIN
0V 5 COMPUTER
6 0V_Sig.ref. / /24.7
EMERGENCY STOP ES1:int 7
/1 .7 h_ h+
7 C V
C 2
1
RELAY SIGNALS 6 8
/R H
H
6. / R 0
/1 un unC
ES2:int
6 C
/R R
6
6 /
ES1 ES2 6. .6
/1 /16

Location: + CM
Sublocation: +
Next 14.1
1 2 3 4 5 6 7 8
PANEL BOARD
-A22
.5
.5
-10062 -X12 24V FPU POWER

/ 24V SYS AWG18 BU 24V SYS
1 24V PANEL
/ 0V SYS -10063 AWG18 BU 0V SYS
2
24V PANEL
/ 24V COOL -10064 AWG18 BU
3
/ 0V COOL -10065 AWG18 BU
4
X10
-X1 -X2 -10070
/52.4 / ES1_EM ES1 top AWG20 ES FPU 1:A /
/52.4 / ES2_EM ES2 top 3 5 -10071 AWG20 ES FPU 2:A / FPU
-10072 AWG20 ES FPU 2:B /
JUMPER
3 7
8 -10073 AWG20 ES FPU 1:B /
/52.2 / CH2_0V 0V 0V 6
/52.2 / CH1_24V 24V Panel 4 24V PANEL
4
RunCh+
RunCh+
Run CH1 top

X9 -S21.3
5
ES1OUT:A -239 AWG20 21 22
ES2 OUT:A 1 17 -240 AWG20
1 18 -241 AWG20 11 12
ES2 OUT:B 13 -242 AWG20
ES1OUT:B 2 14 -243 AWG20
2 11 -244 AWG20
/52.4 / ES2A_EM Sep ES2:A RunCh+ 12 -245 AWG20
/52.4 / ES1A_EM Sep ES1:A 9 RunCh+ 15 -246 AWG20
9 -ES3 16
-ES3
U U
/52.7 / ES1B_EM Sep ES1:B A2 A1

10
/52.7 / ES2B_EM Sep ES2:B A1 A2
10
ES2 bottom
JUMPER
JUMPER
7
-X11
SUPPLY 0V 7
24V Panel 8 1
8 2 OG 24V_Sig.ref. /
SOFT_ESO
24V PANEL 3 WHOG RS485+ /
SOFT_ESI 4 BU RS485- / MAIN
0V 5 COMPUTER
6 WHBU 0V_Sig.ref. /
EMERGENCY STOP ES1:int 7
h +
V
C 2
1
RELAY SIGNALS 6 8
/ RCH
H
C h
/ R _0
un unC
ES2:int
/ R/ R
6 ES1 ES2
Latest revision: Lab/Office: Status: 2008-07-17 Plant: = EUROMAP2

Location: + CM
Sublocation: +
FOR 2 IMM
Next 15
1 2 3 4 5 6 7 8
PANEL BOARD
-A21
-X3 X10 205

General in1 24V SYS 24V FPU POWER AWG20 24V FPU_POWER / /21.2
1 General in2 24V PANEL 1 206 AWG20 0V PANELB / /21.2 FPU
2 General in3 0V SYS 2 207 AWG20 EN1_1 / /21.2
3 General in4 3 208 AWG20 EN1_2 / /21.2
4 General in5 4 213 AWG20 FPU START / /21.2
5 General in6 9
6 General in7
+CM.2-X6
7 General in8 EN2_1A OPTION
8 0V 7 EN2_1B EXTERNAL
9 +24V 8 EN2_2A ENABLE DEVICE -S21.1.X1 3 2 1 4 7 6 5 8
10 9 EN2_2B
10
-X4
General out1
X9
EXT.AUTO2 -A21-245
EXT.MAN2 -A21-244
EXT MAN FS2 -A21-243
EXT.COMMON2 -A21-246
EXT.AUTO1 -A21-241
EXT.MAN1 -A21-240
EXT MAN FS1 -A21-239
EXT.COMMON1 -A21-242
1 General out2 AWG20 -227
2 General out3 8 AWG20 -226
3 General out4 7 AWG20 -225
OPTION:STATUS 4 General out5 6 AWG20 -223
LED ON FRONT 5 General out6 4 AWG20 -222
-A23 6 General out7 3 AWG20 -221
7 General out8 2
MODE
8 0V
9 SELECTOR
-ES2 -S21.1
6 12 10 2 4 8 18 22 24 14 16 20
>1
-ES1
5 1 17 13
AWG26
-SUP_ST2 -X2 WHOG
-X20 -220
1 OG 1 1 -224
-SUP_ST1
2 BU 2 RS485+ 5
4 WHBU 4 RS485-
-GS2 MOTOR ON PB
5 WHGN 5 24V DC
3 GN 3
-S21.2
-GS1 -229
6 WHBN 6 0V 14 13
7 BN 7 10 -228
-AS2
8 8 9
/17.3 / SPEED
/16.6 / EN1
/16.6 / EN2
/16.5 / MAN1
/16.5 / MAN2
-230 X2 X1
-AS1
19
-ENABLE1
EXT.COMPUTER FAN
24V PANEL
-E2
-X15 .7
OP_COM
-E2
OP_MAN 1 -1
-X18 -364 -361 .7 -X18 -X1
3 24V COOL AWG20 AWG20 BU RD
+
2 2 1
OP_AUTO TACHO -362 AWG20 BU BN
M
OP_MAN_FS 2 3 3 2
4 -
FAN 0V -363 AWG20 -360 AWG20 BU BK
1 1 3

Location: + CM.1
Sublocation: +
Next 16
Prepared by, date: JSUNDIN Approved by, date: MTORNROS 3HAC024120-004 Total 48 03
1 2 3 4 5 6 7 8
EM FOR /52.3 / 24V_PANEL

PANEL BOARD
2 IMM
-A21
/52.3 / 0V_PANEL
24V SYS 24V FPU POWER
24V PANEL
0V SYS
RunCh_0V / /14.5
RunCh+ / /14.5
24V PANEL
-X5
MAN2 / /15.4
MAN1 / /15.4
RCH2 / /14.6
RCH1 / /14.6
/48.3 /50.3 / KSD1 :13 1024 24V PANEL
EN2 / /15.4
EN1 / /15.4
12 24V PANEL
6 0V
/48.3 /50.3 / KSD1 :23 1026 7 0V
1
/48.5 /50.3 / KSD1 :14 1027 AS1+
11 AS1
AUTO AS1
STOP &
EM FOR /52.7 / AS1+_EM
2 IMM AS1-
/52.8 / AS2-_EM AS2+ 9 AS2 SOFT AS
5
AS2
/48.6 /50.3 / KSD1 :24 1043 AS2-

GS1+ 3 GS1
10
GS1
GENERAL &
STOP
GS1- SOFT GS
GS2+ 8 GS2 CH2 CH1
4
GS2
GS2-
2
-X6
24V PANEL
6 0V
1
/17.4 / RCH2
/17.4 / RCH1
SS1+ SS1
4
/17.3 / ENABLE2_1
/17.3 / ENABLE2_2
/17.3 / ENABLE2_3
/17.3 / ENABLE2_4
SUPERIOR SS1
STOP
SS1- SOFT SS
SS2+ 2 SS2
5
SS2
SS2-
3

Location: + CM.2
Sublocation: +
Next 17
1 2 3 4 5 6 7 8
CONTROL
PANEL BOARD
MODULE
-A21
/16.7 / RCH1
/16.7 / RCH2
-X7
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret Drive
24V PANEL 4 RUN CH2 module1
/15.4 / SPEED 3 SPEED A43.X1
5 0V
/16.6 / ENABLE2_1 6 ENABLE2_1
7 ENABLE2_1Ret
/16.6 / ENABLE2_2 8 AC_ON1
9 0V
/16.6 / ENABLE2_3 10
/16.6 / ENABLE2_4
-X8
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret
24V PANEL 4 RUN CH2 BU Drive
3 SPEED module2
5 0V if not used A43.X1
6 ENABLE2_2
7 ENABLE2_2Ret BU
9 0V
10
-X14
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret Drive
24V PANEL 4 RUN CH2 BU module3
3 SPEED A43.X1
5 0V if not used
6 ENABLE2_3
7 ENABLE2_3Ret BU
9 0V
10
-X17
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret Drive
24V PANEL 4 RUN CH2 BU module4
3 SPEED A43.X1
5 0V if not used
6 ENABLE2_4
7 ENABLE2_4Ret BU
9 0V
10

Location: + CM.3
RUN CHAIN Approved
Sublocation: +
Next 18
1 2 3 4 5 6 7 8
PANEL BOARD
-A21
-X9 -222 AWG20 BU MAN2 -241 OG EXT.AUTO1

-S21.1.X1
3 7
-221 AWG20 BU AUTO2 -240 OG EXT.MAN1
2 6
7 3
-225 AWG20 BU AUTO1 -244 OG EXT.MAN2 OPTION
6 2
2-MODE
SELECTOR
1
-S21.1
1 3 5 7 9 11 13 15
2 6 .6 10 .6 14
5
-224 AWG20 BU 0V -246 OG EXT.COMMON2
5 4
-220 AWG20 BU 24V panel -242 OG EXT.COMMON1
1 8
MOTOR ON PB
-S21.2
-229 AWG20 BU MOTON 14 13

10
-228 AWG20 24V PANEL
9
-230 AWG20 BU MONLMP X2 X1
19

Location: + CM.4
Sublocation: +
Next 19
1 2 3 4 5 6 7 8
CONTROL
MODULE
-A21 EXT-A21
-X9
-X9 -222 AWG20 -241 -S21.1.X12
EXT.AUTO1
3 3 -221 AWG20 -240 EXT.MAN1 7
2 2 -226 AWG20 -245 EXT.AUTO2 6
7 7 -225 AWG20 -244 EXT.MAN2 3
3 MODE
6 6 2
SELECTOR
-S21.1
3 5 7 9 11 13 15 OPTION
2 6 10 14

5 5 -220 AWG20 -242 EXT.COMMON1 4
1 1 8
MOTOR ON PB
-S21.2
-229 EXT.CONTROL
AWG20 PANEL 14 13
10 10
-230 EXT.CONTROL
AWG20 PANEL X2 X1
19 19 -228 EXT.CONTROL
AWG20 PANEL
9 9
EMERGENCY PB
-S21.3
-231 -248 ES panel 1:A 21 22
17 -232 17 -249 ES panel 1:A
18 -233 18 -250 ES panel 2:A 11 12
13 -234 13 -251 ES panel 2:A
14 14 -252 ES panel 2:B
11 11 -253 ES panel 2:B
12 12 -254 ES panel 1:B
15 15 -255 ES panel 1:B
16 16
1 1
2 2
2 2
-X1 1 1 -X1 -XS1

1 BN/RD 0V 1 -240 0V 1
2 BN/OG EN1 2 -241 EN 1_1 2
3 BN/YE EN2 3 -242 EN 1_2 7
4 -235 4 -243 ES FPU 1:A 17
5 -236 5 -244 ES FPU 1:B 3
6 -237 6 -245 ES FPU 2:A 4 FPU
7 -238 7 -246 ES FPU 2:B 5
9 9 0V 11
EN2 8
12
-A1 ADAPTER -A32.A1
MAIN /24.6 / TD+ TD+ -X1 TD+
A31-A8 /24.6 / RD+ RD+ 2 RD+ 14

/24.6 / RD- RD- 3 RD- 15
6 16

Location: + CM.5
Sublocation: +
Next 20
1 2 3 4 5 6 7 8
CONTROL
MODULE
-A21 EXT.1-A21
-X9
-X9 -S21.1.X13
8 8 -226 AWG20 -244 EXT.MAN2 3
7 7 -225 AWG20 -243 EXT MAN FS2 2
6 6 -223 AWG20 -241 EXT.AUTO1 1
4 4 -222 AWG20 -240 EXT.MAN1 7
3 3 -221 AWG20 -239 EXT.CONTROL PANEL 6
2 2 5
MODE SELECTOR
-S21.1
6 12 10 2 4 8 18 22 24 14 16 20 OPTION
5 1 17 13

5 5 -220 AWG20 -246 EXT.COMMON2 8
1 1 4
EXT.CONTROL PANEL
-S21.2
-229 AWG20 14 13
10 10
-230
AWG20 X2 X1
19 19 -228 AWG20
9 9
EMERGENCY PB
-S21.3
-1 -18 ES panel 1:A 21 22
17 -2 17 -19 ES panel 1:A
18 -3 18 -20 ES panel 2:A 11 12
13 -4 13 -21 ES panel 2:A
14 14 -22 ES panel 2:B
11 11 -23 ES panel 2:B
12 12 -24 ES panel 1:B
15 15 -25 ES panel 1:B
16 16
1 1
2 2
2 2
-X1 1 1 -X10 -XS1

1 BN/RD 0V 1 -10 0V 1
2 BN/OG EN1 2 -11 EN 1_1 2
3 BN/YE EN2 3 -12 EN 1_2 7
4 -5 4 -13 ES FPU 1:A 17
5 -6 5 -14 ES FPU 1:B 3
6 -7 6 -15 ES FPU 2:A 4 FPU
7 -8 7 -16 ES FPU 2:B 5
9 9 0V 11
EN2 8
12
-A1 ADAPTER -A32.A1
MAIN /24.6 / TD+ TD+ -X1 TD+
A31-A8 /24.6 / RD+ RD+ 2 RD+ 14

/24.6 / RD- RD- 3 RD- 15
6 16

Location: + CM.6
Sublocation: +
Next 21
1 2 3 4 5 6 7 8
OPTION:
FPU-PLUG
XP4
1) When external control panel connected to page 19 and 20 -XP1
4
FLEXPENDANT
-FPU1
1) .7
XS4 EMERGENCY-STOP
-K1
/14.7 / ES FPU 1:A -209 AWG20 BU
3
PANEL /14.7 / ES FPU 2:A -211 AWG20 BU
BOARD 5
/14.7 / ES FPU 2:B -212 AWG20
6
/14.7 / ES FPU 1:B -210 AWG20 BU
EN-DEVICE
1 -K2
205 -DP1
1 2
/15.6 / 24V FPU_POWER AWG20 BU
12
206 -DP2
1 2
PANEL /15.6 / 0V PANELB AWG20
BOARD 2
8
/15.6 / EN1_1 207 AWG20
7
/15.6 / EN1_2 208 AWG20
17
/15.6 / FPU START 213 AWG20 BU

11 .7
-
/24.6 / TD+
13
MAIN /24.6 / TD-
COMPUTER 14
A31-A8 /24.6 / RD+ ETH_FPU

15
/24.6 / RD-
16

Location: + CM
Sublocation: +
Next 22
1 2 3 4 5 6 7 8
PANEL BOARD PANEL BOARD

-A21 A21
-X1 -260 -XS/XP3 -X5 -272 -XS/XP3

ES1 bottom OG AWG20 BU 24V PANEL AWG20 BU AWG20 BU
7 A1 12 C1
-X2 -261 -273
ES2 bottom OG AWG20 BU AS1+ AWG20 BU
7 B1 11 C2
24V PANEL -262 AWG20 BU AS1- -274 AWG20 BU AWG20 BU
8 B2 9 C3
0V -263 AWG20 BU 0V -275 AWG20 BU
8 A2 7 C4
24V PANEL -264 AWG20 BU AWG20 BU AWG20 BU
4 A3 C5
Run CH1 top GS1+ -276 AWG20 BU
5 10 C6
Run CH2 top GS1- -277 AWG20 BU AWG20 BU
5 8 C7
0V -265 AWG20 BU AWG20 BU
4 B3 C8
ES2 top -266 OG 24V PANEL -278 AWG20 BU AWG20 BU
3 B4 6 D1
ES1 top -267 AS2+ -279

OG AWG20 BU
3 A4 5 D2
Sep ES1:A -268 OG AWG20 BU AS2- -280 AWG20 BU AWG20 BU
9 A5 3 D3
Sep ES2:A -269 OG AWG20 BU 0V -281 AWG20 BU
9 B5 1 D4
Sep ES2:B -270 OG AWG20 BU
10 B6 D5
Sep ES1:B -271 OG GS2+ -282 AWG20 BU
10 A6 4 D6
ES1 OUT A -284 OG GS2- -283 AWG20 BU AWG20 BU
1 A7 2 D7
ES1 OUT B -285 OG
2 A8 D8
ES2 OUT A -286 OG
1 B7
ES2 OUT B -287 OG
-X6 -289
2 B8 0V AWG20 BU AWG20 BU
1 A10
SS1- -291 AWG20 BU
2 B10
SS2- -293 AWG20 BU
3 C10
SS1+ -290 AWG20 BU
4 B9
SS2+ -292 AWG20 BU
5 C9
24V PANEL -288 AWG20 BU AWG20 BU
6 A9
10

Location: + CM.7
OPTION: EXTERNAL CONNECTION Approved
Sublocation: +
SYSTEM SIGNALS
Next 24
1 2 3 4 5 6 7 8
CONTROL
MODULE
-A31
-A9
TX+ / DRIVE
1 TX- / MODULE
2 RX+ / AXIS
AXC1 3
-X1 COMPUTER
ETH_DRIVE 4
/12.3 / 24V PC 5 RX- /
1 6
PROCESS /12.3 / 24V PC 7
POWER SUPPLY 4 8
/12.3 / 0V PC
2
/12.3 / 0V PC
3
-X1
-A7
PWR LED (GREEN)
TX+ AWG24 WHOG
1 TX- OG 1 SERVICE
2 RX+ WHGN 2 PORT
3 3
ETH_SERVICE 4
5 RX- GN
IDE LED (YELLOW)

6 6
7
8
STATUS LED (RED-GREEN)

_TX+ / OPTION:
_TX- / REMOTE
_RX+ / SERVICE
_RX- /
-X8
AWG24
1
2 OG 24V_Sig.ref. / /14.7
3 WHOG RS485+ / /14.7
PANEL UNIT 4 BU RS485- / /14.7 PANEL BOARD
RS 485 5
6 WHBU 0V_Sig.ref. / /14.7
7
CHASSIS BLOWER 8
-E22
- -A8
M TD+ / /21.2 /20.2 /19.2

3
-J1 TD- / /21.2 /20.2 /19.2
+
GND AWG24 BK ETH_FPU 6 FLEXPENDANT

1 +24V RD 4
2 FAN_TACH YE 5 RD+ / /21.2 /20.2 /19.2
3 1
RD- / /21.2 /20.2 /19.2
2
7
8

Location: + CM
Sublocation: +
Next 25
1 2 3 4 5 6 7 8

-A31 CONTROL
MODULE
-LAN1 -XP1
OPTION: TX+
232/422/485 SERIE CONVERTER 1 TX- 1
-A39 2 2
OPTION : EXTERN LAN
RX+
3 RX- 3
-X1 -X2 COM1
-J2 6 6
RX- A1 COM1_DCD
TX+ 1 1 A2 COM1_RXD
TX- 2 2 A3 COM1_TXD
3 3 A4 COM1_DTR
0V 4 4 A5 0V
5 5 A6 COM1_DSR
6 6 A7 COM1_RTS-N
RX+ 8 8 A9 COM1_RI
9 9
-X2
-USB1
AWG28 GN USB1 D+
3 AWG28 WH USB1 D- 3
USB
4 AWG24 RD USB1 +5V 4 CONTROL MODULE
1 1
MC CONSOLE
-J2
/ CON_DCD CONSOLE_DCD
OPTION: REMOTE SERVICE / CON_RXD B1 CONSOLE_RXD
/ CON_TXD B2 CONSOLE_TXD
/ CON_DTR B3 CONSOLE_DTR
/ CON_GND B4 GND
-USB2
/ CON_DSR B5 CONSOLE_DSR AWG28 GN USB2 D+ / /12.7 PROCESS
/ CON_RTS-N B6 CONSOLE_RTS-N 3 AWG28 WH USB2 D- / /12.7 POWER SUPPLY
/ CON_CTS-N B7 CONSOLE_CTS-N 2 AWG24 BK USB2_GND / /12.7
/ CON_RI B8 CONSOLE_RI 4 AWG24 RD USB2 +5V / /12.6
B9 1

Location: + CM
Sublocation: +
Next 26
1 2 3 4 5 6 7 8
COMPUTER UNIT AC/BD

-A3
COMPUTER UNIT DSQC623
COMPUTER POWER SUPPLY -A31
-G31
-P1 -J4H1
-X1 -X1 OR +3.3V
24V OR +3.3V 1
1 V+ BK GND 2
PROCESS 24V RD +5V 3
POWER SUPPLY 4 BK GND 4
-G2.X3 0V RD +5V 5
2 BK GND 6
0V -G1-PSU-X1 7
3 V- GY PWR_OK
-PSU-X1 1 8
VT +5VSB
-P1 1 9
YE +12V
OR +3.3V 10
BU -12V 11
-PSU-X1 12
MOTHER BK GND
BOARD
2 GN PS_ON 13
POWER -P1 3 14
BK GND
BK GND 15
BK GND 16
17
RD +5V 18
RD +5V 19
20
SOLID STATE DRIVE

-D32 -J6H1
40
-X1 -X2
ATA/IDE
-A1-IDEpwr1 1
GND 2
+5V 3
4
SOLID STATE DRIVE

REMARK:
-D31
P1 & J6H1 CONNECTS
-X2 40
TO EITHER D32 OR D31
-X1
DEPENDING OF CHOSED OPTION.
1
1
GND 2
+5V 3
4

Location: + CM
Next 27
1 2 3 4 5 6 7 8
COMPUTER UNIT AC/BD

-A3
COMPUTER POWER SUPPLY

-G31
P1
BK GND
YE +12V
CHASSIS BLOWER
-E22
M
AWG 24
COMPUTER UNIT DSQC623 -C1
+
-A31 BK GND BK
-J9H1 YE +12V 1 RD
2
1
2 WH FAN2_TACH
3
CHASSIS BLOWER
-E23
-J9H2
1 -
2
3
M
AWG 24
-C2
+
BK GND BK
YE +12V 1 RD
2
WH FAN1_TACH

Location: + CM
Next 28
1 2 3 4 5 6 7 8
COMPUTER UNIT AC/BD

CONTROL
-A3
MODULE
OPTION:
-A31 COMPUTER UNIT DSQC623
232/422/485 SERIE CONVERTER
-A39 PWR LED (GREEN)
-J9H1
A K
-X1 -X2 -J1 COM1 2
RX- COM1_DCD
TX+ 1 1 A1 COM1_RXD 4
IDE LED (YELLOW)
TX- 2 2 A2 COM1_TXD
3 3 A3 COM1_DTR A K
0V 4 4 A4 0V 1
5 5 A5 COM1_DSR
6 6 A6 COM1_RTS-N 3
RX+ 8 8 A8 COM1_RI
9 9 A9 -LAN1
TX+
1 TX-
2 RX+
3 RX-
6
-X24
-USB1
-J2 MC CONSOLE AWG28 GN USB1 D+
B1 CONSOLE_DCD 3 AWG28 WH USB1 D- 3
B2 USB
CONSOLE_RXD CONTROL MODULE
B3 4 AWG24 RD USB1 +5V 4
CONSOLE_TXD
B4 1 1
CONSOLE_DTR
B5
GND
B6
CONSOLE_DSR
B7
CONSOLE_RTS-N -USB2
B8 AWG28 GN USB2 D+
CONSOLE_CTS-N
B9 CONSOLE_RI 3 AWG28 WH USB2 D- PROCESS
2 AWG24 BK USB2_GND POWER SUPPLY
4 AWG24 RD USB2 +5V
-G2.X5
1
-USB3
3
2
4
1
-USB4
3
2
4
1

Location: + CM
Next 29
1 2 3 4 5 6 7 8
COMPUTER UNIT AC/BD DSQC602

-A32
-X8
1
2 WHGN 24V_Sign.ref
3 BU RS485+
RS 485 4 WHBU RS485- PANEL BOARD
5 -A21.X11
6 WHBN 0V_Sign.ref
7
8
-A8
OG TD+
3
WHOG TD- FLEXPENDANT
ETH_FPU 6 -XS4
4
5 GN RD+
1
WHGN RD-
-X1
2
7
8
CONTROL
MODULE
-A9
PCI BUS TX+
1 TX-
2 RX+
3 RX- DRIVE MODULE
ETH_DRIVE 6 AXIS COMPUTER
4
5
7
8
-A7 -X23
TX+ 1
1 TX- 2 SERVICE
2 RX+ 3 PORT
ETH_SERVICE 3
4
5 RX- 6
6
7
8

Location: + CM
ROBOT COMM. CARD DSQC 602
Next 30
1 2 3 4 5 6 7 8
PROFIBUS DP M/S
-A33
Customer
Connection
-X1
-DP-S-X2
SHIELD
RXD/TXD-P 1
SLAVE CONTROL-P 3
PCI BUS GND 4

+5VDC
5
RXD/TXD-N 6
8
-DP-M-X3
SHIELD
RXD/TXD-P 1
MASTER CONTROL-P 3
GND 4
+5VDC 5
RXD/TXD-N 6
8

Location: + CM
PROFIBUS DP M/S Approved
Sublocation: +
Next 31
1 2 3 4 5 6 7 8
INTERBUS M/S (OPTICAL FIBRE) INTERBUS M/S (COPPER WIRE)

EUROMAP
=EUROMAP
CM.1 +CM.1
-A37 INTERBUS M/S (OPTICAL FIBRE) -A38.1
-A37.1 1)
-X4
24V
24V+
.3
0V
1) 0V
-X2
-Z1 24V -Z1
24V+
REMOTE IN -X5
0V DO
0V 1 DON
4 DI
2 DIN
-FO1
PCI BUS LW/BK PCI BUS 5 GNDISI
REMOTE IN
BK1(IN) 3
LW/OG
GY (OUT)

-FO2 -X1

REMOTE OUT
LW/BK DO
REMOTE OUT
BK1(IN) 1 DON
LW/OG DI
6
GY (OUT) 2 DIN
7 GRND
3 VCCISO
5 RBST
9
INTERBUS m/S (COPPER WIRE)
-A37.2
-FO3
LW/BK
REMOTE
BK (IN)
LW/OG
GY (OUT)
INTERBUS M/S (COPPER WIRE)
-A38.2
REMOTE -X2
DO
1 DON
6 DI
2 DIN
7 GNDIM
-X1
TXD 3 GRND
1 RXD 4 VCCIM
2 GND 5 VCC
4 RTS 8
5 CTS
6
RS232 -X3
TXD
1 RXD
2 GND
4 RTS
5 CTS
6
1) IT IS IMPORTANT THAT 24 DC EXT SUPPLY ALWAYS IS AVAILABLE

OTHERWISE THE INTERBUS CAN NOT WORK
IF THE CONTROLLER IS TURNED OFF.

Location: + CM.1
INTERBUS M/S Approved
Sublocation: +
Next 32
1 2 3 4 5 6 7 8
CONTROL
MODULE
-A35
.4
/33.3
-CHA-J1 -A35 -XS17
.1 -X1
P1 BK
1 1 3
BU
2 2 5
SC
3 3 1
WH OPTION
4 4 4
PCI BUS RD
5 5 2
V- / /33.2
CAN_L / /33.2
DRAIN / /33.2
CAN_H / /33.2
V+ / /33.2
Only for dual DEVNET card DSQC 659
-CHB-J2
2
Customer option bus
3

Location: + CM
Sublocation: +
Next 33
1 2 3 4 5 6 7 8
-I/O1
/32.5 / V-
/32.5 / CAN_L 1
/32.5 / CAN_H 2
/32.5 / V+ 3
/32.5 / DRAIN 4 BK V- / /36.1
5 BU CAN_L / /36.1
WH CAN_H / /36.1 Digital I/O unit
RD V+ / /36.1
-I/O2
SC DRAIN / /36.1
1
2 BK V- / /39.2
3 BU CAN_L / /39.2
4 WH CAN_H / /39.2 Relay I/O unit
5 RD V+ / /39.2
SC DRAIN / /39.2
-I/O3
BK V- / /42.1
1 BU CAN_L / /42.1
2 WH CAN_H / /42.1 Analogue I/O unit
3 RD V+ / /42.1
4 SC DRAIN / /42.1
5
BK V- / /43.1 OPTION: HARNESS
BU CAN_L / /43.1 TO CUSTOMER I/O
-I/O4
WH CAN_H / /43.1 Remote I/O unit
1 RD V+ / /43.1
2 SC DRAIN / /43.1
3
4 BK V- / /44.2
5 BU CAN_L / /44.2
WH CAN_H / /44.2 Interbus slave
RD V+ / /44.2
SC DRAIN / /44.2
BK V- / /45.1
-A35
BU CAN_L / /45.1
/32.1 -X2
/13.2 / 0V devicenet WH CAN_H / /45.1 Profibus DP slave
1 RD V+ / /45.1
SC DRAIN / /45.1
2
120 OHM BK V- / /46.1
3 BU CAN_L / /46.1
WH CAN_H / /46.1 Encoder unit
4 RD V+ / /46.1
/13.2 / +24V devicenet SC DRAIN / /46.1
5

Location: + CM
Sublocation: +
Next 34
1 2 3 4 5 6 7 8
DUAL RS232 CARD

-A34
-X1
1 CONSOLE_RXD
2 CONSOLE_TXD
CONSOLE_DTR
3
MC CONSOLE 4 0V
RS232 5 CONSOLE_DSR
6 CONSOLE_RTS-N
7 CONSOLE_CTS-N
8
X5 9
-X2
1 COM1_RXD
PCI BUS 2 COM1_TXD
3 COM1_DTR
COM1 4 0V
RS232 5 COM1_DSR
6 COM1_RTS-N
7 COM1_CTS-N
8
9

Location: + CM
DUAL RS232 CARD Approved
Sublocation: +
Next 35
1 2 3 4 5 6 7 8
ETHERNET CARD
-A36
-A1
TX+
1 TX-
2 RX+
4
5 RX-
X1 6
7
8
-A2
TX+
1 TX-
PCI BUS 2 RX+
4
5 RX-
6
7
8
-A3
TX+
1 TX-
2 RX+
4
5 RX-
6
7
8

Location: + CM
ETHERNET CARD Approved
Sublocation: +
Next 36
1 2 3 4 5 6 7 8
TO NEXT
I/O UNIT
0VDC:IMM / /13.5
2)
120 ohm
3) 2 1
/13.3 / +24V devicenet DIG. PART OF COMBO I/O AND DIG. I/O UNIT DSQC 651& 652
-I/O1
XTXX.X3
X3
K 1 INPUT CH.1 1030 I/O1 X3:1 / /48.3 /52.2 /52.6
1 2 1034 I/O1 X3:2 / /48.4 /52.2 /52.6
1 2
A
2 3 1035 I/O1 X3:3 / /48.4 /52.2 /52.6
3 4 1036 I/O1 X3:4 / /48.4 /52.3 /52.6
-X5
/33.5 / V- K 1 A 4 5 1037 I/O1 X3:5 / /48.5 /52.3 /52.7
/33.5 / CAN_L 1 5 6 1028 I/O1 X3:6 / /48.3 /52.1 /52.5
2
/33.5 / CAN_H 2 6 7 1033 I/O1 X3:7 / /48.4 /52.2 /52.6
/33.5 / V+ 8 1029 I/O1 X3:8 / /48.3 /52.1 /52.5

4 1 7
5 8 0V 1055
/33.5 / DRAIN 9
0V 3 10
OR PREVIOUS NA0 6
I/O UNIT NA1 7 0V

1) NA2 8
NA3 9
NA4 10 XTXX.X4 4)
NA5 11
X4
12 K A INPUT CH.9 1044 I/O1 X4:1 / /48.6 /50.6 /52.4 /52.8
1 10 1031 I/O1 X4:2 / /48.3 /50.4 /52.2 /52.6
2 11 1045 I/O1 X4:3 / /48.6 /50.6 /52.4 /52.8
A
3 12 1061 I/O1 X4:4 / /48.6 /50.6 /52.4 /52.8
4 13 1062 I/O1 X4:5 / /48.6 /50.6 /52.4 /52.8
A 5 14
6 15 1038 I/O1 X4:7 / /48.5 /50.5 /52.3 /52.7
1) JUMPERS PLACED ACCORDING TO 7 16 1039 I/O1 X4:8 / /50.5 /48.5 /52.3 /52.7
THE ACTUAL NODE ADDRESS. 8 0V 1060
9
10

CAN-BUS CIRCUIT.
4) ONLY FOR DIGITAL I/O DSQC 652

Location: + CM
DIGITAL PART OF COMBI I/O AND Approved
Sublocation: +
DIGITAL I/O UNIT
Next 37
Prepared by, date: JSUNDIN Approved by, date: MTORNROS 3HAC024120-004 Total 48 03
1 2 3 4 5 6 7 8
24VDC:IMM / /47.7 /51.8 /49.7

0VDC:IMM / /47.7 /51.8 /49.7
-I/O1UNIT
/39.4
OUTPUT CH 1-8
XTXX.X1
1
<1 -X1
OUTPUT CH.1 1047 OUTP CH1 / /47.3 /51.4 /51.6
47nF K 1 2 1048 OUTP CH2 / /47.4 /51.6 /51.5
A 2 3 1011 I/O1 X1:3 / /47.4 /51.2 /51.6
3 4 1012 I/O1 X1:4 / /47.4 /51.2 /51.6
4 5 1014 I/O1 X1:5 / /47.5 /51.3 /51.7
2
5 6 1013 I/O1 X1:6 / /47.4 /51.3 /51.6
A
6 7 1004 I/O1 X1:7 / /47.3 /51.2 /51.6
47nF
K 7 8 1005 I/O1 X1:8 / /47.3 /51.2 /51.6
2 1 8 0V 1020
0V 9 24V DC 1008
10
OUTPUT CH 9-16
XTXX.X2
1
<1 -X2
OUTPUT CH.9 1064 I/O1 X2:1 / /47.3 /51.1 /51.5 /49.3
47nF K 1 10
A 2 11 1066 I/O1 X2:3 / /47.6 /49.6 /51.4 /51.8
3 12 1067 I/O1 X2:4 / /47.6 /49.6 /51.4 /51.8
4 13 1068 I/O1 X2:5 / /47.6 /49.6 /51.4 /51.8
2
5 14 1069 I/O1 X2:6 / /47.6 /49.6 /51.4 /51.8
A
6 15 1015 I/O1 X2:7 / /47.5 /49.5 /51.3 /51.7
47nF
K 7 16 1016 I/O1 X2:8 / /47.5 /49.5 /51.3 /51.7
2 1 8 0V 1021
9 24V DC 1009
10

Location: + CM.1
DIGITAL I/O UNIT Approved
Sublocation: +
Next 38
1 2 3 4 5 6 7 8
COMBI I/O UNIT

I/Ox
OUTPUT CH 1-8
XTXX.X1
A
<1 -X1
OUTPUT CH.1
K 1 2
2 3
3 4
4 5
2
5 6
A
6 7
K 7 8
1 2 8 0V
0V 9 24V DC
10
-X6
INPUT CH.1
CPU INPUT CH.2 1
2
K K
A A
0V
3
DAC
OUTPUT CH.1
5
REF 0VA
4
OUTPUT CH.2
6
+15V
DC
0VA
DC
-15V

Location: + CM.2
COMBI I/O UNIT Approved
Sublocation: +
Next 39
1 2 3 4 5 6 7 8
TO NEXT
I/O UNIT
2)
120 ohm
2 1
3) UNIT
-I/O1
/13.3 / +24V devicenet /37.2
/13.3 / 0V devicenet XTXX.X3

-I/Ox1-X3
K 1 INPUT CH.1 1077 R.I/O.X3:1 / /50.4
1 2 1078 R.I/O.X3:2 / /50.5
1 2
47nF
2 3 1079 R.I/O.X3:3 / /50.5
-I/Ox1-X5 A
3 4 1080 R.I/O.X3:4 / /50.5
/33.5 / V- K 1 A 4 5 1081 R.I/O.X3:5 / /50.5
/33.5 / CAN_L 1 5 6 1082 R.I/O.X3:6 / /50.4
2
/33.5 / CAN_H 2 6 7 1083 R.I/O.X3:7 / /50.5
/33.5 / V+ 8 1084 R.I/O.X3:8 / /50.4

4 1 7
5 8 0V 1085 0VDC:IMM / /13.5
/33.5 / DRAIN 9
0V 3
OR PREVIOUS NA0 6
I/O UNIT NA1 7 0V

1) NA2 8
NA3 9
NA4 10
NA5 11
12



CAN-BUS CIRCUIT.

Location: + CM.1
Sublocation: +
Next 40
1 2 3 4 5 6 7 8
RELAY I/O UNIT

-RELAY I/O1
XTXX.X1
-X1
OUT CH.1A 1086 24VDC:IMM /
1
OUT CH.1B 1070 R.I/O.X1.2 / /49.1

2
OUT CH.2A
3
OUT CH.2B 1071 R.I/O.X1.4 / /49.1

4
OUT CH.3A
OUT CH.3B 1072 R.I/O.X1.6 / /49.1

6
OUT CH.4A
7
OUT CH.4B 1073 R.I/O.X1.8 / /49.1

8
OUT CH.5A
9
OUT CH.5B 1074 R.I/O.X1.10 / /49.1

10
OUT CH.6A
11
OUT CH.6B 1075 R.I/O.X1.12 / /49.1

12
OUT CH.7A
13
OUT CH.7B 1076 R.I/O.X1.14 / /49.1

14
OUT CH.8A
15
OUT CH.8B 1087 R.I/O.X1.16 / /49.1

16

Location: + CM.2
Sublocation: +
Next 42
1 2 3 4 5 6 7 8
TO NEXT
I/O UNIT
2) ANALOGUE I/O UNIT

I/Ox
120 ohm
2 1 .5
ANALOGUE I/O UNIT

3)
-X7
ANOUT_1
/13.3 / +24V devicenet .4 1 ANOUT_2
/13.3 / 0V devicenet 2 ANOUT_3
ADC MUX
3 ANOUT_4
4 0V
19 0V
0V 20 0V
21 0V
-X5
/33.5 / V- 22
/33.5 / CAN_L 1
/33.5 / CAN_H
2
/33.5 / V+ 4
5
/33.5 / DRAIN
0V 3 REF
DAC
OR PREVIOUS NA0 6
-X8
I/O UNIT NA1 7 ANIN_1
1) NA2 8 1 ANIN_2
NA3 9 2 ANIN_3
NA4 10 3 ANIN_4
NA5 11 4
12 24V
17
18
19
20
21
0V 22
1) JUMPERS PLACED ACCORDING TO 23

25 0V
26 0V
27 0V

CAN-BUS CIRCUIT.

Location: + CM.2
ANALOGUE I/O UNIT Approved
Sublocation: +
Next 43
1 2 3 4 5 6 7 8
TO NEXT
I/O UNIT
2)
120 ohm
2 1
3)

REMOTE I/O UNIT
I/Ox
-X5
/33.5 / V-
/33.5 / CAN_L 1 NAC
/33.5 / CAN_H 2
-X8
/33.5 / V+ LINE 1 (BLUE)
4
5 1 REMOTE I/O IN
/33.5 / DRAIN
0V 3 LINE 2 (CLEAR)
OR PREVIOUS NA0 6 1 2
I/O UNIT NA1 7

-X9
1) NA2 8 (BLUE)
NA3 9 1 REMOTE I/O OUT
NA4 10
NA5 11 (CLEAR)
12 2
3
-X8
3
1
1
THE ACTUAL NODE ADDRESS. 2
2

LAST CONNECTOR IN THE CAN-BUS CIRCUIT. -X9
4
CAN-BUS CIRCUIT.

Location: + CM.2
REMOTE I/O UNIT Approved
Sublocation: +
Next 44
1 2 3 4 5 6 7 8
TO NEXT
I/O UNIT
2)
120 ohm
2 1
3)
/13.4 / +24V devicenet INTERBUS SLAVE

I/Ox
-X5
/33.5 / V-
-X21
/33.5 / CAN_L 1 TPDO2
/33.5 / CAN_H 2 1 TPDI2
/33.5 / V+
4 2 GND
5 3 +5VDC IB-S OUT
/33.5 / DRAIN 5 TPDO2-N
0V 3 6 TPDI2-N
OR PREVIOUS NA0 6 7 RBST
I/O UNIT NA1 7 9
1) NA2 8
NA3 9
NA4 10
NA5 11
12
-X20
TPDO1
1 TPDI1
2 GND IB-S IN
3 TPDO1-N
6 TPDI1-N
-X3
GND 7
4) 24V DC EXT. SUPPLY 1
+24VDC 3
5


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.

Location: + CM
INTERBUS SLAVE Approved
Sublocation: +
Next 45
1 2 3 4 5 6 7 8
TO NEXT
I/O UNIT
2)
120 ohm
2 1
PROFIBUS DP SLAVE
3) I/Ox

/13.4 / 0V devicenet Customer
Connection
-X5
/33.5 / V-
-X20
/33.5 / CAN_L 1 SHIELD
/33.5 / CAN_H 2 1
/33.5 / V+
4 RXD/TXD-P
5 3 CONTROL-P
/33.5 / DRAIN 4 GND
0V 3 5 +5VDC
OR PREVIOUS NA0 6 6 RXD/TXD-N
I/O UNIT NA1 7 8
1) NA2 8
NA3 9
NA4 10
NA5 11
12
-X3
0V DC
External supply GND 1
+24VDC 3
5



CAN-BUS CIRCUIT.

Location: + CM
PROFIBUS DP SLAVE Approved
Sublocation: +
Next 46
1 2 3 4 5 6 7 8
TO NEXT
I/O UNIT
2)
120 ohm
2 1
ENCODER UNIT
I/Ox
3)
/13.4 / +24V devicenet Encoder

/13.4 / 0V devicenet Connection
-X20
24 VDC
1
-X5
/33.5 / V- 0V
/33.5 / CAN_L 1 2
/33.5 / CAN_H 2 ENC +24V
/33.5 / V+
4 3
5 ENC 0V
/33.5 / DRAIN 4 Encoder
0V 3 2 1 ENC_A
OR PREVIOUS NA0 6 5
NA1 7 A
I/O UNIT ENC_B
1) NA2 8
1
6
NA3 9 +24V
NA4 10 7
NA5 11 0V Synch switch
12 2 1 8
DIGIN
A 9
2 1
A
1

CAN-BUS CIRCUIT.

Location: + CM
ENCODER UNIT Approved
Sublocation: +
Next 47
Latest revision:
1
Prepared by, date:

JSUNDIN
2
Approved by, date:

-XS13
1000 NA1.1:IRB / /14.2
A1
1001 NA2.1:IRB / /14.2
A2
MTORNROS
1002 XT8:1 / /9.2
A3
A4
1064 I/O1 X2:1 / /37.6
3
A5
1003
11
12 14
A6
1004 I/O1 X1:7 / /37.6
-24K1
A7
1022 1047 OUTP CH1 / /37.6
A2
A1
1005 I/O1 X1:8 / /37.6
A8
1006
A9
B1
1007
1010
11
12 14
4
B2
1011 I/O1 X1:3 / /37.6
B3
-24K2
1012 I/O1 X1:4 / /37.6
B4
1023 1048 OUTP CH2 / /37.6
A2
A1
1013 I/O1 X1:6 / /37.6
B5
1014 I/O1 X1:5 / /37.6
Lab/Office:
B6
B7
1015 I/O1 X2:7 / /37.6
1016 I/O1 X2:8 / /37.6

B8
5
XS13
B9
1017 NA1.2:IRB / /14.2

C1
1018 NA2.2:IRB / /14.2

C2
1019 XT8:3 / /9.2

C3
C4
1066 I/O1 X2:3 / /37.6

Sh. 47 when EMP67
C5
1067 I/O1 X2:4 / /37.6

6
C6
1068 I/O1 X2:5 / /37.6

C7
1069 I/O1 X2:6 / /37.6

C8
1020
C9
1008
Status:
7
Document no.
Approved
Plant: 2008-07-17
0VDC:IMM / /37.7
24VDC:IMM / /37.7
Location:
3HAC024120-004
Sublocation: +
+ CM
8
03
= EUROMAP
Total 48
Next 48
Rev. Ind Page 47
Latest revision:
1
Prepared by, date:

JSUNDIN
2
Approved by, date:

-XS13Z
1025 KN1:13 / /14.2
A1
1040 KN1:23 / /14.2
A2
MTORNROS
1024 KSD1 :13 / /16.2
A3
1026 KSD1 :23 / /16.2
A4
1028 I/O1 X3:6 / /36.7
3
A5
1029 I/O1 X3:8 / /36.7
A6
1030 I/O1 X3:1 / /36.7
A7
1031 I/O1 X4:2 / /36.7
A8
1032 XT31 :2 / /13.5
A9
B1
1033 I/O1 X3:7 / /36.7
4
B2
1034 I/O1 X3:2 / /36.7
B3
1035 I/O1 X3:3 / /36.7
B4
B5
1036 I/O1 X3:4 / /36.7
1037 I/O1 X3:5 / /36.7
Lab/Office:
B6
1038 I/O1 X4:7 / /36.7

B7
1039 I/O1 X4:8 / /36.7

B8
5
XS13Z
B9
1042 KN1:14 / /14.2

C1
1041 KN1:24 / /14.2

C2
1027 KSD1 :14 / /16.2

C3
1043 KSD1 :24 / /16.2

C4
1044 I/O1 X4:1 / /36.7

C5
1061 I/O1 X4:4 / /36.7

6
C6
1062 I/O1 X4:5 / /36.7

C7
1045 I/O1 X4:3 / /36.7

C8
1046 XT31 :4 / /13.5

C9
Status:
7
Document no.
Approved
Plant: 2008-07-17
Location:
3HAC024120-004
Sublocation: +
+ CM
8
03
= EUROMAP
Total 48
Next 49
Rev. Ind Page 48
1 2 1076 3 4 5 6 7 8
-I/O.X1
/40.6 / R.I/O.X1.2 1070
1
/40.6 / R.I/O.X1.4 1071
2
1008 24VDC:IMM / /37.7
0VDC:IMM / /37.7
1047
1007
1048
+CM-24K3 +CM-24K4
12 14 A1 12 14 A1
11 A2 11 A2
1022
1023
/40.6 / R.I/O.X1.6 1072

3
/40.6 / R.I/O.X1.8 1073
4
/40.6 / R.I/O.X1.10 1074
5
/40.6 / R.I/O.X1.12 1075
6
/40.6 / R.I/O.X1.14 1076
7
/40.6 / R.I/O.X1.16 1087
8
NA1.1:IRB / /14.2
NA2.1:IRB / /14.2
NA1.2:IRB / /14.2
NA2.2:IRB / /14.2
I/O1 X2:1 / /37.6
I/O1 X2:7 / /37.6
I/O1 X2:8 / /37.6
I/O1 X2:3 / /37.6
I/O1 X2:4 / /37.6
I/O1 X2:5 / /37.6
I/O1 X2:6 / /37.6

XT8:1 / /9.2
XT8:3 / /9.2
1000
1001
1002
1064
1003
1004
1005
1006
1010
1011
1012
1013
1014
1015
1016
1017
1018
1019
1066
1067
1068
1069
1020
+CONVERTOR -X13 A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 B8 B9 C1 C2 C3 C4 C5 C6 C7 C8 C9 PE
EMP67
+CONVERTOR -X13B- 19 27 18 25 29 17 28 30 32 20 21 22 24 23 26 31 PE
EMP12

Location: + CB
CONVERTER BOX Approved
Sh. 49 when EMP12 Sublocation: +
EUROMAP 67/12
Next 50
Latest revision:
1
Prepared by, date:

JSUNDIN
2
Approved by, date:

KN1
-X13A
-X13Z
1025 KN1:13 / /14.2
1
14
11
A1
1042 KN1:14 / /14.2
C1
KN1
MTORNROS
1040 KN1:23 / /14.2
3
24
21
A2
1041 KN1:24 / /14.2
C2
.6
1024 KSD1 :13 / /16.2
3
14
11
A3
1027 KSD1 :14 / /16.2
C3
.6
1026 KSD1 :23 / /16.2
24
21
A4
1043 KSD1 :24 / /16.2
C4
-I/O1.X3
1028 1082 R.I/O.X3:6 / /39.7

6
8
A5 1029 1084 R.I/O.X3:8 / /39.7
8
12
A6
1030 1077 R.I/O.X3:1 / /39.7

1
2
4
A7
1031 I/O1 X4:2 / /36.7
14
A8
1032 XT31 :2 / /13.5
16
A9
B1
1033 1083 R.I/O.X3:7 / /39.7

7
Lab/Office:
10
B2
1034 1078 R.I/O.X3:2 / /39.7

2
4
B3
1035 1079 R.I/O.X3:3 / /39.7

3
5
B4
5
1036 1080 R.I/O.X3:4 / /39.7

4
6
B5
1037 1081 R.I/O.X3:5 / /39.7

5
7
B6
1038 I/O1 X4:7 / /36.7

B7
-KSD1
1039 I/O1 X4:8 / /36.7
EUROMAP 67/12
B8
CONVERTOR BOX
A1
A2
11
B9
1044 I/O1 X4:1 / /36.7

13
C5
1061 I/O1 X4:4 / /36.7

6
C6
1062 I/O1 X4:5 / /36.7

C7
-KN1
1045 I/O1 X4:3 / /36.7

15
C8
1046 XT31 :4 / /13.5

9
A1
A2
C9
Status:
7
Document no.
Approved
Plant: 2008-07-17
Location:
3HAC024120-004
Sublocation: +
+ CB
8
03
= EUROMAP
Total 48
Next 51
Rev. Ind Page 50
(XP13.2)
-XS13
-XS13.2
1000 1209
Latest revision:
A1
1
1001 1208
Prepared by, date:

1
A2
1002 XT8:1 / /9.2
A3
1064 I/O1 X2:1 / /37.6
JSUNDIN
A5
ES2B_EM / /52.6
1003 ES1B_EM / /52.6
A6
1004 I/O1 X1:7 / /37.6 SR_CH2 / /52.6
A7
1005 I/O1 X1:8 / /37.6 SR_CH1 / /52.5
A8
1006
2
1216
1217
1208
1209
1201
1200
1204
1205
A9
1010
B1
A1
B2
61
51
41
31
21
11
Approved by, date:

1011 I/O1 X1:3 / /37.6
-SR
B3
62
52
42
32
22
12
1012 I/O1 X1:4 / /37.6

B2
A2
SAFTY RELAY
B4
1013 I/O1 X1:6 / /37.6
MTORNROS
1219
1218
1211
1210
1213
1212
1221
1220
B5
1014 I/O1 X1:5 / /37.6 SR_CH1 / /52.6
B6
1015 I/O1 X2:7 / /37.6 SR_CH2 / /52.6
B7
3
1016 I/O1 X2:8 / /37.6
B8
ES1B_EM / /52.7
1017 1210 ES2B_EM / /52.6
C1
1018 1211
C2
1019 XT8:3 / /9.2
C3
1066 I/O1 X2:3 / /37.6
C5
1067 I/O1 X2:4 / /37.6
C6
4
1068 I/O1 X2:5 / /37.6
C7
11
12 14
1069 I/O1 X2:6 / /37.6
C8
-24K3
1020 1022 1047 OUTP CH1 / /37.6

A2
A1
C9
Lab/Office:
1007
(XP13.2)
-XS14
-XS13.22
11
12 14
1000 1217
2
A1
1001 1216
-24K4
1
5
A2
1002 XT8:1 / /9.2 1023 1048 OUTP CH2 / /37.6
A2
A1
A3
1064 I/O1 X2:1 / /37.6
FOR 2 IMM
I/O2
A5
EUROMAP 67
1003
11
12 14
A6
1004 I/O1 X1:7 / /37.6

-24K5
I/O2
A7
1022 1047 OUTP CH1 / /37.6

A2
A1
1005 I/O1 X1:8 / /37.6 I/O2

A8
1006
A9
1007
6
1010
11
12 14
B2
1011 I/O1 X1:3 / /37.6

B3
-24K6
1012 I/O1 X1:4 / /37.6

B4
1023 1048 OUTP CH2 / /37.6

A2
A1
1013 I/O1 X1:6 / /37.6 I/O2

I/O2
B5
1014 I/O1 X1:5 / /37.6

B6
1015 I/O1 X2:7 / /37.6

Status:
B7
1016 I/O1 X2:8 / /37.6

7
B8
Document no.
Approved
1017 1218
3
C1
2008-07-17
1018 1219
4
1008
C2
1019 XT8:3 / /9.2

C3
1066 I/O1 X2:3 / /37.6

Plant:
C5
Location:
3HAC024120-004
1067 I/O1 X2:4 / /37.6

I/O2
C6
Sublocation: +
1068 I/O1 X2:5 / /37.6

+ CB
C7
8
03
1069 I/O1 X2:6 / /37.6

C8
0VDC:IMM / /37.7
24VDC:IMM / /37.7
1020
= EUROMAP2
C9
Total 48
Next 52
Rev. Ind Page 51
1125
-XS13Z
A1
1140
Latest revision:
A2
1
1124
Prepared by, date:

A3
1126
A4
(XS13.1)
1028 I/O1 X3:6 / /36.7
JSUNDIN
A5
4
3
2
1
1029 I/O1 X3:8 / /36.7
A6
-XP13.1
1030 I/O1 X3:1 / /36.7
A7
1031 I/O1 X4:2 / /36.7
A8
1203
1202
1207
1206
1032 XT31 :2 / /13.5
2
A9
1033 I/O1 X3:7 / /36.7
(XP13.1)
B2
-XS13.1
Approved by, date:

1034 I/O1 X3:2 / /36.7 1200 CH1_24V / /14.1.2
1
B3
1035 I/O1 X3:3 / /36.7 1201 CH2_0V / /14.1.2
2
B4
1036 I/O1 X3:4 / /36.7 24V_PANEL / /16.2
3
MTORNROS
B5
1037 I/O1 X3:5 / /36.7 0V_PANEL / /16.2
4
B6
1038 I/O1 X4:7 / /36.7
B7
3
1039 I/O1 X4:8 / /36.7
B8
-XP13.3/XS13.1
1142
1
C1
1141
2
C2
1127
3
C3
1143
4
(XS13.2)
C4
-XP13.2
1044 I/O1 X4:1 / /36.7 1204 ES2_EM / /14.1.2

1
C5
4
1061 I/O1 X4:4 / /36.7 1205 ES1_EM / /14.1.2

2
C6
1062 I/O1 X4:5 / /36.7 ES1A_EM / /14.1.2
3
C7
1045 I/O1 X4:3 / /36.7 ES2A_EM / /14.1.2
4
C8
1046 XT31 :4 / /13.5
C9
Lab/Office:
1125
A1
-XS14Z
1140
A2
1124
5
A3
1126
A4
1028 I/O1 X3:6 / /36.7
FOR 2 IMM
A5
EUROMAP 67
1029 I/O1 X3:8 / /36.7
I/O2
A6
SR_CH1 / /51.2
1030 I/O1 X3:1 / /36.7
A7
SR_CH2 / /51.2
1031 I/O1 X4:2 / /36.7
A8
ES2B_EM / /51.1
1032 XT31 :2 / /13.5
A9
ES1B_EM / /51.1
6
1033 I/O1 X3:7 / /36.7

B2
SR_CH1 / /51.3
1034 I/O1 X3:2 / /36.7
B3
SR_CH2 / /51.3
1035 I/O1 X3:3 / /36.7
B4
ES2B_EM / /51.3
I/O2
1036 I/O1 X3:4 / /36.7

B5
ES1B_EM / /51.3
1037 I/O1 X3:5 / /36.7
B6
1038 I/O1 X4:7 / /36.7

Status:
B7
1039 I/O1 X4:8 / /36.7

7
(XP13.3)
(XS13.3)
B8
-XS13.32
-XP13.3
Document no.
Approved
1142 1220 1212 ES1B_EM / /14.1.2

1
1
C1
2008-07-17
1141 1221 1213 ES2B_EM / /14.1.2

2
2
C2
1127 1214 AS1+_EM / /16.2

3
3
C3
1143 1215 AS2-_EM / /16.2

Plant:
4
4
C4
Location:
3HAC024120-004
1044 I/O1 X4:1 / /36.7

C5
Sublocation: +
1061 I/O1 X4:4 / /36.7

+ CB
C6
8
03
I/O2
1062 I/O1 X4:5 / /36.7

C7
1045 I/O1 X4:3 / /36.7

Next
= EUROMAP2
C8
Total 48
Rev. Ind Page 52
1046 XT31 :4 / /13.5

C9
Index
A I
additional drive module 102 I/O units and gateways, repair 208
axis computer, repair 282 Inspection of controller modules 170
Installation Activities 36
B
Installation of Drive system parts 111
backup energy bank, repair 211 Installation of extra mass memory 119
bolt pattern 41 Installation of I/O, Gateways and encoder units 113
busbar, repair 280 installation space 40
C IRC5 controller modules 36
capacitor 88 L
capacitor, repair 279 lifting device 37
Cleaning of the IRC5 controller 176
Cleaning the FlexPendant 179 M
computer unit 119 Main cable 67
computer unit, repair 222 main power
Configuration of the drive system 88 switching off 28
Connecting a USB memory 97 main switch
connection control module 28
FlexPendant 51 controller cabinet 28
Connection of external safety devices 15 drive module 28
Connectors on controller 47 Memory functions 96
contactor auxilary blocks 75 motherboard 230
contactor Interface Board, repair 297 MOTORS ON/MOTORS OFF 74
Control power supply, Repair 187 MOTORS ON/MOTORS OFF circuit 68
controlled stop 18 Multi Move system 102
D O
Drive functions 87 Operating conditions 38
drive system fan, repair 300
P
drive system power supply, repair 199
Drive unit Node 94 panel boardt, repair 184
drive units 88 PC, connecting 52
DSQC 612 ethernet board 103 Power supply 61
Dual Cabinet Controller, overview 35, 183 Protection class 38
protective stop 24
E
R
Electronic Position Switches 152, 285
emergency stop 23 rectifier, repair 279
EPS board 152, 285 rectifiers 88
ESD Replacement of computer power supply 275

damage elimination 29 Replacement of computer unit fan 259
sensitive equipment 29 Replacement of Contactor Interface Board 297
wrist strap connection point 29 Replacement of customer I/O power supply 193
Ethernet 54 Replacement of hard disk and IDE Flash module 268
Euromap 123 Replacement of main computer 230
explanation, safety symbols 26 Replacement of PCI cards 245
external operator’s panel 106 S
external safety relay 73
Safety Controller 152, 285
F safety stop 24
filters 88 Safety, service 15
Fitting the connector 65 safety, symbols 26
FlexPendant service port 52
connecting 51 servo disconnect 80
servo drive units 88
H servo drive units, repair 279
hardware stops 18 Single Cabinet Controller, overview 35, 183
Heat exchange unit and fan, repair 218 standard, overview 35, 183
stop category 0 18
stop category 1 18

Index
stop connections
overview 18
stop modes
overview 18
stops
overview 18
Storage conditions 38
symbols, safety 26
U
uncontrolled stop 18
USB ports 97, 98
V
Validity and responsibility 15
W
Weight 38

3HAC021313-001, Revision K, en
ABB AB
Robotics Products
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592

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Product manual

Document ID: 3HAC021313-001

© Copyright 2004-2008 ABB. All rights reserved.

© Copyright 2004-2008 ABB All rights reserved.

2 Installation and Commissioning, IRC5 35

2.4.1 Required installation space, IRC5 Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.5.15 Connecting a Limit switch override push button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

3 Maintenance activities, controller IRC5 169

4 Repair activities, controller IRC5 183

4.11 Replacement of motherboard in computer unit DSQC623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

5 Reference information, IRC5 313

6 Spare Parts 321

6.2.2 Manipulator cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

7 Circuit Diagram 341

About this manual

Who should read this manual?

Product manual - IRC5 3HAC021313-001

Continues on next page

Minor corrections made in section Installation of Euromap.

Installation of Hot plug button is described in the new section

New Backup energy bank unit is included in section

New DeviceNet Master/Slave boards are included in sections:

© Copyright 2004-2008 ABB. All rights reserved.

Circuit diagram is updated to revision 6.

New safety section Close the cabinet door added.

New section Connecting the communication cabeling to the

Minor corrections made.

Continues on next page

New option Dust filter is described in the new section

New option EtherNet/IP Fieldbus Adapter is described in the

New power supplies are described in the new sections

Circuit diagram for option EuroMap and SPI added.

Minor corrections made.

Minor corrections made.

Changes made in section Maintenance schedule, controller

Changes made in section Installation of Euromap.

Updates made with IRB 360 in sections:

New option Remote Service is described in the new section

Minor corrections made.

Circuit diagram updated to revision 2.

Continues on next page

Instructions how to replace the brake resistor bleeder in the Dual

© Copyright 2004-2008 ABB. All rights reserved.

Product documentation, M2004

Technical reference manuals

• RAPID Overview: An overview of the RAPID programming language.

Continues on next page

© Copyright 2004-2008 ABB. All rights reserved.

1.2 General safety information

© Copyright 2004-2008 ABB. All rights reserved.

1.2.2. General Information

1.2.2.1. Safety in the robot system

Validity and responsibility

Connection of external safety devices

Type of information Detailed in document Section

1.2.3. Safety risks

1.2.3.1. Risks associated with live electric parts

Voltage related risks, general

Voltage related risks, IRC5 controller

Voltage related risks, tools, material handling devices, etc

1.2.4. Safety actions

1.2.4.1. Fire extinguishing

1.2.5. Safety stops

1.2.5.1. Overview of robot stopping functions