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8 Trouble Shooting

8.3 Fault Symptoms and Malfunctions

178

3HNA009834-001 en Rev.06

Product Manual, Control Cabinet IRC5P

8.3.4 Controller Dead

Description

The robot controller is completely or intermittently ‘dead’.

No indicators are lit and no operation is possible.

Consequences

The system can not be operated.

Possible Causes

The symptom may be caused by (the causes are listed in order of probability):

•

The controller is not connected to the mains power supply.

•

The main transformer is malfunctioning or not connected correctly.

•

The mains overload protection (FR1) may have tripped.

Recommended Actions

Step Action

Comment

Make sure the mains power supply in the shop
is working and that the voltage level matches
that of the controller requirement.

The installation documentation may
provide this as well as other vital
information.

Make sure the main transformer has been
correctly connected for the mains voltage level
at hand.

How to connect the transformer is found
under

’Mains Power Connection’

page 115..

Make sure the mains overload protection, FR1
has not tripped. If it has, reset it.

For information, see ‘Unit Description,
IRC5P’, Power Module / Fuses and
Overload Protections.

Check that the other fuses in the power supply
system are OK.

For information, see ‘Unit Description,
IRC5P’, Power Module / Fuses and
Overload Protections.

If the system does not start although the
controller seems to be working, make sure all
connections have been made correctly
between the modules.

Summary of Contents for IRC5P

Page 1: ...The heart of Robotics Product Manual Control Cabinet IRC5P 3HNA009834 001 en Rev 06 ...

Page 2: ......

Page 3: ...Product Manual Control Cabinet IRC5P 3HNA009834 001 en Rev 06 First Edition 10 Dec 2007 Last Revised 08 October 2010 Product Manual Control Cabinet IRC5P ...

Page 4: ...ty 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 or of the software and hardware described in this document We reserve all rights in this document and in the information contained therein Reproduction use or disclosure to third parties without express authority is strictly forbidden Additional co...

Page 5: ...External Connection Overview 45 5 2 Component Installation 46 5 2 1 Introduction 46 5 2 2 Lifting and Transporting the Controller 47 5 2 3 Cabinet Location 48 5 2 4 Purge Unit Installation 49 5 3 System Interconnections 51 5 3 1 Electrical Interconnections IRB 5500 52 5 3 2 Electrical Interconnections IRB 52 IRB 5400 IRB 580 IRB 540 55 5 3 3 IS Ground Connection 59 5 3 4 Connectors 61 5 4 Robot Sa...

Page 6: ...ystem Battery 127 6 6 Check the Cooler 128 7 Repair 129 7 1 Introduction 129 7 2 Replacement of Control Panel Board CPB 131 7 3 Replacement of System LED Board ALED 133 7 4 Replacement of Door Fan Unit 135 7 5 Replacement of Axis Computer PDB PIB SIB MIB SCB 137 7 6 Replacement of Pendant Interface Board TIB 139 7 7 Replacement of I O Units 141 7 8 Replacement of Computer Unit 143 7 9 Replacement ...

Page 7: ...eflashing Firmware Failed 185 8 3 12 Inconsistent Path Accuracy 186 8 3 13 Consistent Path Inaccuracy 187 8 3 14 Oil or Grease Stains on Motors and or Gearboxes 188 8 3 15 Mechanical Noise 189 8 3 16 Manipulator Collapses on Power Down 190 8 3 17 Robot Brakes do not Release 191 8 4 Trouble Shooting Instructions per Unit 192 8 4 1 Trouble Shooting the Pendant 192 8 4 2 Trouble Shooting Power Supply...

Page 8: ...8 3HNA009834 001 en Rev 06 Product Manual Control Cabinet IRC5P Table of Contents Product Manual Control Cabinet IRC5P ...

Page 9: ...instructions for performing preventive maintenance and repair WARNING Before performing any work described in this manual the Safety Manual must be read and understood Work must only be performed by skilled personnel with the proper training The Safety Manual is included in the Software and Documentation DVD following each robot and is also shipped with the robot as paper copy included in the cont...

Page 10: ...10 3HNA009834 001 en Rev 06 Product Manual Control Cabinet IRC5P ...

Page 11: ...red knowledge of mechanical and electrical installation maintenance and repair work Organization of Chapters The manual is organized in the following chapters Chapter Description 1 Introduction This chapter 2 Safety Safety information which must be studied before performing any work on the system 3 System Description Information on design of the controller pendant and purge unit 4 Technical Specif...

Page 12: ... Description Safety Manual 3HNA008924 001 This manual must be read before any work on the robot is performed Unit Description IRC5P 3HNA009628 001 Includes technical description of the control system electronics etc Unit Description Paint 3HNA012856 001 Includes technical description of the units used in the paint system Operator s Manual IRC5P 3HNA008861 001 Includes instructions for setting up c...

Page 13: ...s intended as a short reference and is no substitute for reading the complete Safety Manual The robot is a powerful machine Always make sure that nobody is within the reach of the robot when running the robot for test etc Releasing the robot axis brakes can be potentially dangerous Never release the brakes unless you know the risks involved The robot is normally installed in a hazardous area where...

Page 14: ...2 Safety 14 3HNA009834 001 en Rev 06 Product Manual Control Cabinet IRC5P ...

Page 15: ...e control cabinet pendant and purge unit WARNING Repair work on the control cabinet must only be performed in accordance with procedures given in the Repair chapter in this manual References For detailed description of the function of the different control systems in the control cabinet and purge unit see Unit Description IRC5P For detailed description of the operation of the pendant see Operator ...

Page 16: ... that the control panel is to be installed in an external control desk or that the robot is controlled from an external PLC via serial lines Side panel door Mains switch Emergency stop button Control panel LED indicator panel Front door Hour counter Cable entrances Pendant and suspension Service connections Service outlet optional Identification plate Pendant connection Door interlock optional Mai...

Page 17: ...USB memory stick CAUTION Only memory sticks recommended by ABB must be used Using other memory sticks than recommended may cause RobotWare system failure For more information on the service connections see Operator s Manual IRC5P Installation and Commissioning Connections Pendant The pendant Paint Teach Pendant Unit PTPU or TPU is used to perform robot near tasks like jogging For description see P...

Page 18: ...13 X 4 X 8 X 9 X 1 0 X 1 1 X1 2 X7 X 5 X 6 X 2 X 1 X 3 X 1 3 X4 X8 X 9 X 10 X 11 X 1 2 X 7 X8 X7 X6 X5 X4 X21 X26 X27 X14 X15 X13 X12 X25 X10 X9 X11 X3 X16 X17 X18 X24 X23 X22 X1 X2 MIB 01 X19 X20 X18 X8 X7 X6 X5 X4 X21 X26 X27 X14 X15 X 1 3 X 1 2 X 2 5 X10 X9 X11 X3 X16 X17 X24 X23 X22 X1 X2 X19 X20 X18 M I B 0 1 SIB 01 X5 X1 X10 X15 X16 X17 X6 SIB 01 PIB 01 PIB 01 BCPU SDI 03 R e se r v e d fo r...

Page 19: ...unit 2 Mains power switch 27 Brake resistor bleeders 3 Control panel board CPB 28 Power distribution board PDB 4 Additional rectifier unit ARU 29 Rail for mounting optional units 5 Additional drive unit ADU axis 7 30 Door fan unit 6 Mode selector 31 Transformer 7 Additional drive unit ADU axis 8 32 CAN1 2 for external distributed I O 8 CBS drive units 33 CAN1 1 for internal distributed I O 9 Manip...

Page 20: ...purge sensor and battery supply for the manipulator measuring system Safety Connection Board SCB The Safety Connection Board SCB includes connections for the various safety functions for the robot and also connections for encoders and external panel The board includes only connectors and no active components Pendant Interface Board TIB The Pendant Interface board TIB is a connection board for rout...

Page 21: ...X2 etc and terminal boards are labelled XT1 XT2 etc A connector or terminal board located on one of the cabinet panels is labelled with the designation of the panel in addition to the name of the connector or terminal board e g 2 XT1 which means terminal board XT1 located on the cabinet back wall AC2 A connector or terminal board located on one of the units in the cabinet is labelled with the name...

Page 22: ... purge unit called Purge Unit with Connector Box is used This purge unit includes a purged chamber with cable connections The main reason for using this type is to provide flexible cables via the trolley cable chain For information on this purge unit type see Purge Unit w Connector Box on page 111 Purge supply to dry filtered air only instrumental air Purge pressure WARNING PRESSURIZEDAIR Note 3 b...

Page 23: ...wn in Product Manual Manipulator Figure 6 Control cabinet identification plate Figure 7 Purge unit identification plate 0470 APPROVED Type CONTROL CABINET IRC5P NEMKO 02ATEX273U Temperature Supply Voltage Supply Current Consumption Batch Serial No II 2 G Ex ib px Intrinsically Safe Outputs for Cl I Cl II Div 1 Gr C D G Ref Dwg No 3HNA012652 001 PO Box 265 N 4349 Bryne ABB AS Robotics II 2 D Ex ibD...

Page 24: ... 001 Ta 10 C 40 NEMKO 08ATEX1188 IECEx NEM 08 0003 Instrinsically safe apparatus for Cl 1 Div 1 Gr C D T4 135 C II 2 G Ex ib IIB T4 0470 APPROVED NEMKO Nr Ex 08ATEX1188 Ex ib IIB for Cl 1 Div 1 Gr C D Drawing 3HNA012823 001 II 2 G Box 265 N 4349 Bryne NORWAY ABB AS Robotics Intrinsically Safe Outputs in accordance with U 50V M U1 C uF o I A o U V o L mH o 7V 0 07 300 25 IIB U2 7V 0 0214 300 250 U3...

Page 25: ...X21 MANIPULATOR INTERFACE BOARD MIB X10 X13 X12 X25 PART OF W CONTROL DRAWING Purge System 3HNE 06486 1 Measurement System 3HNE 08898 1 X26 X27 X14 X15 X16 X17 X18 X4 X5 X6 X7 X8 X24 X23 X22 X21 X3 X20 X1 X2 X19 LEDS X28 X9 RS485_1 RS485_2 SPI f master SPI to slave Dig I O CAN CAN 0470 APPROVED Type PSIB 3HNA010414 001 NEMKO 04ATEX1243 Batch Serial No EEx ib IIB Tamb 60 Intrinsically Safe Outputs ...

Page 26: ...atch Serial No EEx ib IIB Tamb 60 C NEMKO 04ATEX1243 Intrinsically Safe Outputs Ref Dwg No 3HNA015815 001 II 2 G D PO Box 265 N 4349 Bryne NORWAY ABB AS Robotics Class I II Div 1 Um 250V Un 24VDC Vo 12 3V Io 13 7mA Po 42mW Group IIB Ca Co 16 2uF La Lo 600mH Warning Substitution of components may impair intrinsic safety Must only be used with ABB Robots X6 X7 X5 X1 X8 Group C D G ...

Page 27: ...es SH4 SB5 Used to enable I or disable 0 electrical power for the manipulator axis motors The indicator in the on button will be lit when power is applied Motor on is one of many conditions for applying power The Motor On switch is also used to reset the emergency stop chain and to enable run chain in Manual mode Continuous light Ready for program execution Fast flashing light 4Hz The robot is not...

Page 28: ...en operating within the working area of the robot the switch shall always be in Manual mode and the operator shall keep the key with him so it is not possible for other persons to take over control of the robot IMPORTANT In Manual High Speed mode the System Speed is by default set to a low value This is a safety feature to avoid a high speed surprise in case the key switch was set one notch too fa...

Page 29: ...e For detailed description of the operation of the pendant see Operator s Manual IRC5P Figure 13 Pendant design The pendant is connected to the pendant connector at the bottom front of the control cabinet Optionally the pendant may also be connected via hot plug connection or external pendant connection For further information see Pendant Connection on page 103 Important If the pendant is not conn...

Page 30: ...3 System Description 3 4 Pendant Description 30 3HNA009834 001 en Rev 06 Product Manual Control Cabinet IRC5P ...

Page 31: ...roduction 4 Technical Specifications 4 1 Introduction About this Chapter This chapter provides technical specifications on the IRC5P Controller Pendant and Purge Unit WARNING Repair work on the controller must only be performed in accordance with procedures given in the Repairs chapter in this manual ...

Page 32: ...s Service connections available on front of the cabinet door Dimensions See Figure 14 Weight 180 200 Kg Depending on supplied options Airborne noise level 70 dB A Leq acc to Machinery directive MD 2006 42 EC The sound pressure level outside the working space Color specification Grey NCS 2502B Ingress protection degree IP54 Ambient temperature Max 48 C Temperature for complete robot system during t...

Page 33: ...he DSQC 378 together with the IPS you can define 368 2 inputs and 368 outputs Type Name Function AD Combi I O DSQC 651 8 digital in 8 digital out 2 analog out Digital I O DSQC 652 16 digital in 16 digital out 1 Relay I O DSQC 653 8 digital in 8 digital out Digital I O 120 VAC DSQC 654 8 digital in 8 digital out Analog interface board ANIB 8 analog in 4 analog out 4 digital out Digital Sensor inter...

Page 34: ...roduct Manual Control Cabinet IRC5P Dimensions Controller dimensions are shown in the illustration below Figure 14 Controller dimensions 725 650 500 190 Min 100 Min 100 Top view Bottom view foot print 638 360 725 650 Side view Front view 4 x Ø14 157 5 122 5 1450 710 All dimensions in mm ...

Page 35: ... Ingress protection degree IP54 Ambient temperature 10 C 40 C Display 3 TFT LCD dynamic color screen RGB 240 x 320 pixels 8 22 vertical lines Live handle Safety handle to enable the manipulator motion Emergency stop button Safety button for instantly stopping the manipulator motion Thumb joysticks Two thumb operated joysticks to control the manipulator axes Green key group Buttons for menu navigat...

Page 36: ...ed in section Purge Unit w Connector Box on page 111 General Specifications Protection Gas Air Pressure and Consumption Dimensions purge unit See Figure 16 Dimensions purge unit w connector box See Figure 57 Purging sequence time Depending on robot type For information see manipulator identification label Product Manual Manipulator System Description Dew point 2 C at 6 bar Solid particle size 5 mi...

Page 37: ...E CONNECTOR BOX Dwg No 3HNM 01201 1 Part of PURGE SYSTEM Dwg No 3HNE 06486 1 NEMKO 02ATEX189U Protective gas Instrumental air Purge Supply pressure Min 3 0 max 5 0 bar Maintenance Supply pressure Min 0 5 max 1 0 bar Leaquage Compensation 5 20 Nl min Maintenance pressure Min 0 8 mbar Enclosure Pressure Max 500 mbar Batch Serial No INTRINSICALLY SAFE SIGNALS Cl I II Div 1 Gr A G EEx pib IIB II 2 G D...

Page 38: ...4 Technical Specifications 4 4 Purge Unit Specifications 38 3HNA009834 001 en Rev 06 Product Manual Control Cabinet IRC5P ...

Page 39: ...mportant that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes danger and safety risks when performing the procedures Read the Safety Manual before performing any installation work WARNING No installation work must be performed on the robot before the safety guidelines in the Safety Manual have ...

Page 40: ...n the supplied DVD ROM This is information such as various manuals circuit diagrams and spare parts catalogue For complete information see README file on DVD ROM Preparing the Installation Site Before you start the installation it is recommended that you make necessary drawings to establish location of manipulator control cabinet and other components to be installed designing a solid mounting base...

Page 41: ...tor and purge unit to the controller is described in section System Interconnections on page 51 7 Connect IS Ground For information on how to connect IS Ground see IS Ground Connection on page 59 8 Connect safety system for production or test How to perform required connections for the safety system is described in Robot Safety System Connections on page 64 9 Perform cabin safety system connection...

Page 42: ...5 X6 X2 X 1 X3 X13 X4 X8 X9 X10 X1 1 X12 X7 X5 X 6 X2 X1 X 3 X1 3 X4 X8 X9 X1 0 X11 X12 X7 X 8 X 7 X 6 X 5 X 4 X 2 1 X 2 6 X 2 7 X 1 4 X 1 5 X 1 3 X 1 2 X 2 5 X 1 0 X 9 X 1 1 X 3 X 1 6 X 1 7 X 1 8 X 2 4 X 2 3 X 2 2 X 1 X 2 MIB 01 X 1 9 X 2 0 X 1 8 X 8 X 7 X 6 X 5 X 4 X 2 1 X 2 6 X 2 7 X 1 4 X 1 5 X 1 3 X 1 2 X 2 5 X 1 0 X 9 X 1 1 X 3 X 1 6 X 1 7 X 2 4 X 2 3 X 2 2 X 1 X 2 X 1 9 X 2 0 X 1 8 M I B 0 ...

Page 43: ...s on page 51 10 X20 Pendant connection Pendant Connection on page 103 11 Optional internal light Supply for Internal Light on page 118 12 Door switch Supply for Internal Light on page 118 and Cabinet Cooler Installation on page 105 13 PDB X18 External 24V 24 VDC for External Use on page 120 14 Optional field bus nodes Unit Description IRC5P 15 XT65 CAN1 2 for external distributed I O Unit Descript...

Page 44: ...on page 78 SCB X4 Ext emy stop chain supply Robot Safety System Connections on page 64 SCB X5 Encoder input 1 Encoder and Sync Switch Installation on page 86 SCB X6 Encoder input 2 Encoder and Sync Switch Installation on page 86 SCB X7 Encoder input 3 Encoder and Sync Switch Installation on page 86 SCB X8 Remote panel connection Remote Panel Connections on page 99 SCB X9 Remote panel connection Re...

Page 45: ... Sync Switch Installation on page 86 Distributed I O Different field bus nodes are available for connection of digital and analog I O field bus nodes for communication with PLC etc For information on connections etc see Unit Description IRC5P Distributed I O Ethernet Communication Ethernet can be used to connect a PC to the controller for download of robot programs configurations backup etc Ethern...

Page 46: ...tion 5 2 1 Introduction About this Section This section provides information for installation of the control cabinet and purge unit and information for performing necessary system interconnections Following sections are available Installing the control cabinet Installing the purge unit Perform system component interconnections IS Ground connection ...

Page 47: ...rry use a fork lift and transport the cabinet to the installation site or as close to the site as possible before removing it from the pallet 2 Unpack the supplied packages and check that the content is correct and undamaged 3 Place the cabinet on the floor and remove packing material WARNING Do not walk under the hanging load 4 Transport the cabinet to its permanent location using an overhead cra...

Page 48: ...back and sides This is especially important where the ambient temperature approaches the specified maximum For temperature higher than specified maximum additional cooling device is required For information on controller temperature range see Controller Specifications on page 32 Cooler For installation of cooler see Cabinet Cooler Installation on page 105 Protection Standard The cabinet enclosure ...

Page 49: ...pecified by the customer It is recommended to install locate the purge unit preliminary and wait with finding the final position until after the cables have been laid Flexible Hose Layout The flexible hose is normally laid in a cable conduit The hose is resistant to solvents CAUTION The flexible hose must not be stretched as this will put strain on the internal cables which can not be stretched in...

Page 50: ...ation and connections Purge Air Hose Connection The hose between the purge valve unit and purge connection must be maximum 10 meters but can be cut to required length If the hose needs cutting make sure that the end with the orifice inside the hose is not cut off This is also marked on the hose The hose must not be joined in a manner which will restrict the air supply Spray booth Hazardous area Su...

Page 51: ...ll robot types and configurations CAUTION Bonding connections of external electronic components must be properly performed Ref Bonding Information on page 211 The electrical interconnections are depending on manipulator type Connections for the different manipulator types are described as follows Electrical Interconnections IRB 5500 on page 52 Electrical Interconnections IRB 52 IRB 5400 IRB 580 IR...

Page 52: ... DC power cable to connector PDB X20 7 Connect communication robot cable to connector MIB X4 X20 X111 Communication robot Purge valve connector AX1 YV1 Intrinsically safe signals Purge unit valve assembly X6 Purge air hose Robot DC power Purge valve X22 X4 MIB Pump power Control cabinet 1 For non ex process cabinet the purge connection is integrated in the process cabinet 2 Process cabinet is only...

Page 53: ...BS purge valve cable to connector MIB X7 Connect CBS power cable to connector X211 Connect CBS communication cable to connector MIB X5 Connect CBS intrinsically safe signals cable to connector MIB X24 purge sensor and X23 SMU battery power Important If you disconnect X21 23 SMU battery power after the robot has been calibrated revolution counter updated you will have to re calibrate the robot 11 F...

Page 54: ...X13 X10 X6 X7 X11 X14 X15 X1 X16 X4 X18 X23 X2 X3 X5 X25 X24 AC TEMP PC SYS I O FAN BRAKE ULTRA CAP HV P OWER D IS T R IBU T IO N BOAR D PDB ABB AS Robotics X 12 X 13 X 9 X 10 X 8 X 17 X 6 X 7 X 11 X 14 X 15 X 1 X 5 X 2 X 3 X 18 X 23 X 16 X 4 X 25 X 24 X 21 X 20 Power Distribution Board PDB PDB Motor 1 6 driver CBS Communication CBS Robot 3 X2 X19 Drive syst 04 KA110 X21 ADU Purge sensor X24 Intri...

Page 55: ... interconnections IRB 52 IRB 5400 IRB 580 IRB 540 2 Connect purge valve cable to connector AX1 YV1 on purge unit X12 X11 X111 Communication robot Purge valve connector AX1 YV1 Intrinsically safe signals Purge unit valve assembly X6 Purge air hose Robot power Purge valve X22 X4 MIB Pump power Control cabinet Pump power Communication pressure sensors 1 Connection for pumps in robot 2 Connection for ...

Page 56: ...nect pump power cable to connector X111 and communication pressure sensors cable to connector PIB X9 10 If the paint robot is equipped with an inline CBS robot see Figure 25 Connect CBS power cable to connector X211 11 If the paint robot is equipped with a non inline CBS robot see Figure 26 Connect CBS purge valve cable to connector MIB X7 Connect CBS power cable to connector X211 Connect CBS comm...

Page 57: ... CBS robot X12 X11 Communication robot CBS Purge valve connector AX1 YV1 Intrinsically safe signals Purge unit valve assembly X6 Purge air hose Robot power Purge valve X22 X4 MIB Control cabinet X21 SMU battery power Purge sensor Flexible hose Paint Robot Purge connection is integrated in the CBS robot Connector bracket on cabinet left side wall Air conn X211 CBS power CBS Robot ...

Page 58: ...Purge unit valve assembly X6 Purge air hose Robot power Purge valve X22 X4 MIB X5 Control cabinet X21 SMU battery power Purge sensor Flexible hose Paint Robot Purge connection Connector bracket on cabinet left side wall Air conn X211 CBS power CBS Communication CBS Robot Purge sensor X24 Intrinsically safe signals X23 SMU battery power Purge connection is integrated in the CBS robot X7 Purge valve...

Page 59: ...actory IS ground rail Purge unit IS ground screw factory IS ground rail Manipulator IS ground screw factory IS ground rail Remove connection in control cabinet between PE ground rail and IS ground rail Yellow green wire marked blue Alternative B If a separate IS ground rail connected to the factory IS ground is not available Connect an IS ground wire of minimum 10mm AWG 6 between IS ground screws ...

Page 60: ... Notes If the optional external pendant connection is used the connector is grounded via a ground wire in the cable If required an additional ground wire can be installed as shown in Figure 27 The PE ground rail in the control cabinet is connected to the factory PE ground by means of the ground wire in the mains supply cable ...

Page 61: ...wall Figure 28 Location of connectors Identification of the signals in the above connectors can be found on the following pages Conn Description Comment X11 Motor power for manipulator Standard connector Not used for IRB 5500 X12 24VDC for manipulator Standard connector Not used for IRB 5500 X111 Paint pumps in manipulator pump cabinet or 8th axis connector Optional connector X211 CBS robot Option...

Page 62: ... W 7 M2 U1 25 M6 U 8 M2 U2 26 M6 V 9 M2 V1 27 M6 W 10 M2 V2 28 M7 U1 11 M2 W1 29 M7 U2 12 M2 W2 30 M7 V1 13 M3 U1 31 M7 V2 14 M3 U2 32 M7 W1 15 M3 V1 33 M7 W2 16 M3 V2 34 17 M3 W1 35 PE 18 M3 W2 36 PE 28 9 1 36 Connector Signal name 1 24V Power MCOB 2 24V Power brake 3 24V Brake release emy ext 4 0V Brake release emy ext 5 0V Power MCOB 6 24V Power function 7 0V Power function 8 Manipulator enable...

Page 63: ...V1 10 4 PM2 U M8 V2 11 5 PM2 V M8 W1 12 6 PM2 W M8 W2 13 7 14 8 15 PE 1 3 13 15 Connector Signal name Signal name 1 M1 U AXIS 1 13 POWER BRAKE RELEASE EMY EXT 2 M1 V AXIS 1 14 GND 3 M1 W AXIS 1 15 GND 4 M2 U AXIS 2 16 POWER FUCTION 5 M2 V AXIS 2 17 POWER SAFETY 6 M2 W AXIS 2 18 NC 7 M3 U DCU PUMP MOTOR 19 RUN CHAIN 1 OUT 8 M3 V DCU PUMP MOTOR 20 RUN CHAIN 2 OUT 9 M3 W DCU PUMP MOTOR 21 RUN CHAIN 1...

Page 64: ...ING All connections in the safety system must be performed in accordance with the following description The Safety Chains The system has 2 safety chains related to the robot as listed below Emergency Stop Chain Run Chain The function and connections in these chains are described in the following The system also has safety chains and interlock functions related to the cabin and process equipment Th...

Page 65: ... must be applied after breaking the emergency stop chain before motor power can be re applied The run chain does not require a reset signal Emergency Stop Category 0 Emergency Stop Category 0 stops the robot by immediate removal of power to the axis motors and activating the axis brakes Different types of emergency stop category 0 are available External Emergency Stop General Mode Stop and Auto Mo...

Page 66: ...mergency stop chain will fulfil these requirements provided that the correct types of switches are used These switches must be as follows Switches used for Emergency Stop General Mode Stop and Auto Mode Stop must be of positive opening contact type according EN IEC 60204 1 and EN IEC 60947 5 1 Additionally installed External Emergency Stop switch es must be of a type which will be locked after ope...

Page 67: ...ult connected for Internal 24VDC Supply If it is required to have the emergency stop chain operative when the robot is switched off the chain may be connected to External 24VDC Supply as described in section Emergency Stop Chain Supply on page 70 2 If required install Emergency Stop Switch es Category 0 in addition to the Emergency Stop Switches on the main panel and pendant For information see 1 ...

Page 68: ...plant s emergency stop system General Mode Stop Category 0 or Delayed Stop Category 1 in the Run Chain may be used instead of the normal Emergency Stop function For information on this connection see section General Mode Stop Category 0 on page 74 alternatively Delayed Stop Category 1 on page 74 5 If required install External Emergency Stop Reset Button s or connect reset input to the plants emerg...

Page 69: ... safety switches MUST BE PROPERLY INSTALLED 1 Check that links are installed as shown in Figure 30 2 Install a 2 pole switch for Auto Mode Stop as shown in Figure 30 WARNING The auto mode stop switch simulates the spray booth entrance door interlock The switch must be placed in conjunction with a fence etc in such a way that no person can get inside the working area for the robot switch closed wit...

Page 70: ... stop system is connected in the plant emergency stop system External power for the emergency stop chain can be connected to connections marked Ext Emy Stop Chain Supply in connector SCB X4 pin 1 2 as shown in Figure 29 and in principle diagram in Figure 31 External Emergency Stop Category 0 This is a connection where the user may implement one or more normally closed positive opening switches in ...

Page 71: ...y stop chains into the plant emergency stop chain An emergency stop in the robot can thereby be used to activate the plant emergency stop The relay switches to be used for this purpose are galvanically isolated from the rest of the emergency stop chain in the robot The switches are closed when the robot emergency stop chains in the robot are OK To include the robot s emergency stop chain in an ext...

Page 72: ...VDC Emy stop panel EXT_ES1 SCB X1 1 SCB X1 2 KA10 Pendant emy stop EXTERNAL EMY STOP Cat 0 KA12 Emy stop relays KA1 9 KA11 KA28 Internal reset 24VDC Run chain 1 SCB X2 9 SCB X2 10 KA6 13 KA15 KA29 SCB X2 11 SCB X2 12 24VDC EXT_ES2 KA14 Chain 1 Chain 2 SCB X4 1 SCB X4 2 EXT EMY STOP RESET EXT EMY STOP CHAIN SUPPLY 24VDC GND 24VDC SCB X1 3 SCB X1 4 KA11 KA15 Run chain 2 EMERGENCY STOP FEEDBACK Chain...

Page 73: ...e Auto Mode Stop function will remove power from the robot when the mode selector is in Automatic mode Typical use of this function is as safety switch for the spray booth entrance door to allow for a person to enter the spray booth for test or programming when the robot is in Manual Reduced High Speed mode If the spray booth has more entrances switches must be installed in series for all entrance...

Page 74: ...rinciple diagram in Figure 32 The switch must be of a type which will be closed when activated The switch must comply with Safety System Standards on page 65 Delayed Stop Category 1 Delayed Stop is a Category 1 stop and is a controlled stop function which will allow the robot control system to stop the motion of the robot while the robot is running in the programmed path After a category 1 stop th...

Page 75: ...ased or pressed too hard The switch must comply with Safety System Standards on page 65 The enabling device must comply with EN ISO 10218 1 6 4 6 Important These connection points are not Ex protected If used in a hazardous area the enabling device must fulfill the requirements for such use Hardware Motor On Hardware Motor on is the signal which will apply power to the robot when all conditions fo...

Page 76: ...evice TEST MODE STOP Cat 0 24VDC EXT_TMS2 KA26 SCB X1 11 SCB X1 12 24VDC EXT_AMS1 SCB X1 5 SCB X1 6 KA18 AUTO MODE STOP Cat 0 24VDC EXT_AMS2 KA23 SCB X1 7 SCB X1 8 KA16 KA17 Motor on off 24VDC EXT_DS1 SCB X2 5 SCB X2 6 KA19 DELAYED STOP Cat 1 24VDC EXT_DS2 KA24 SCB X2 7 SCB X2 8 24VDC EXT_GMS1 SCB X2 1 SCB X2 2 KA20 GENERAL MODE STOP Cat 0 24VDC EXT_GMS2 KA25 SCB X2 3 SCB X2 4 KA11 KA15 Emy stop 2...

Page 77: ...ve and must only be used in emergency situations Figure 33 Emergency brake release switch design and connection A 24VDC power supply capable of supplying minimum 4 Ampere is required for this function If the switch is to work also by power failure the power supply must be battery backed 1 Install a normally open switch and 24VDC power supply between pin 1 and 2 in connector X24 on the PDB board as...

Page 78: ...rmed in accordance with the following description The Safety Chains The system has various safety chains and interlock functions related to the cabin and the process equipment as listed below The function and connections in these chains are described in the following Cabin Interlock High Voltage Interlock System 2 Interlock Process Interlock Emergency Shut Down Valve The system also has 2 safety c...

Page 79: ...n functions are not present like cabin ventilation For information see Cabin Interlock on page 80 2 Connect High Voltage Interlock switches on the cabin entrance door to prevent people from entering the cabin when high voltage is on For information see High Voltage Interlock on page 81 3 If required install System 2 Interlock switch for bell applicator paint pumps or DCU CBS For information see Sy...

Page 80: ...ed by 24V_MAN will not be affected by the cabin interlock chain Typical connections to these modules are color change etc Which functions that are interlocked and not interlocked can be found in the Process Diagram When breaking the cabin interlock chain the system will use approx 1 2 second to make a controlled stop of the paint functions When closing the chain power will be re applied to the int...

Page 81: ...ut main panel or remote panel or if the high voltage interlock switch is not installed on the panel Following conditions must be present to close the high voltage interlock chain High voltage interlock chain must be closed Cabin interlock chain must be closed Cabin ventilation fans must be running The emergency stop and enable chain must be closed Robot must be purged purge relay must be closed In...

Page 82: ...otation if the bell applicator is used Description To activate the chain following functions must be active in addition to the Manual Pump Interlock switch Cabin interlock A B Cabin interlock chain A and B must be closed CPU pump HW enable Control systems are running and OK Emergency stop Emergency stop must not be activated Pump fuse Pump fuse must not have tripped Connections To install the Syst...

Page 83: ...n interlock chain the high voltage supply to the paint applicator same function as the high voltage interlock and functions controlled by the Safety 2 System Interlock The process interlock may be used by the plant s control system for the cabin e g to close all hazardous functions of the paint system in case of a fire etc Connections To install the Process Interlock switch install a switch at ter...

Page 84: ...terlock Chain Process Interlock Chain High Voltage Interlock Chain 2 High Voltage Interlock Chain 1 24V_IO FUNC_PWR Purge relay SAFETY2_PWR 24V_HV High Voltage Controller HVC 6 Cabin interlocked valves 8 Cabin interlocked valves MCOB 02 VCD1 VCD2 General IO controlled valves SAFETY1_PWR Pump motors DCU CBS FlexShield etc 24V_FUNC 24V_MAN Power Distribution Board PDB EXT_CAB_ILCK1 EXT_HV_ILCK1 EXT_...

Page 85: ...f an emergency Figure 36 Emergency shut down valve principle diagram Basic Function To open the valve following conditions must be present Emergency stop must not be activated Purging sequence must be completed and the robot ready for operation The run chain must be closed Connections Install emergency shut down valve Connect valve to terminal XT2 pin 1 24VDC and 2 GND Install voltage suppression ...

Page 86: ...portant Considerations To ensure good operation of the tracking function following points must be observed The robot or robots and trolley rail system if used must be installed as accurately as possible which normally means at about 0 5 mm maximum deviation from theoretical positions If robots are installed on both sides of the conveyor the robots and rails must also be installed symmetrically rel...

Page 87: ...ween 1250 and 5000 cycles per meter In the following we use this notion Counts cycles 4 pulse transitions The robot motion controller uses all the pulse transitions so that the number of increments used will be 4 times the number of full cycles from the encoder The system specifies only one count per cycle in the parameter see pulse diagram in Figure 37 This means that the controller will read 500...

Page 88: ...ngly dependent on cable quality and cable length Recommended cable is 3 pair screened cable Encoder Noise Suppression The encoder must be connected using a screened cable If this cable is long the inductance in the cable will produce spike pulses on the encoder signal which may over a period of time damage the opto couplers in the control electronics The spike pulses which can be of considerable a...

Page 89: ... reliable and repeatable signal for the work objects on the conveyor regardless of conveyor speed The switch arrangement must be designed so that it only gives one signal for each work object and that it does not give any signal if the work object should happen to pass the switch in backwards direction If the switch gives multiple signals when an object passes the parameter SyncFilter can be set s...

Page 90: ...encoder or for connection of a second sync switch as shown in the illustration The optional components must be configured explicitly Note The system supports 24VDC encoders If RS422 encoders are used a signal converter such as BLE 01 must be used Extra encoders can be used for a second conveyor a backup encoder or for monitoring of paint flow e g when using Küppers initiators For more information ...

Page 91: ...nnected to the shaft of the conveyor drive wheel or one of the wheels of the auxiliary chain Important The encoder must not be connected directly to the conveyor drive unit itself as play in the drive belt will not be registered and if the drive belt should break the robot will operate as if the conveyor was still running Using Flexible Coupling The connection can be performed either directly to t...

Page 92: ...net as shown above and in Figure 38 The 2 phases A 0 and B 90 must be connected so that the encoder counts up when the conveyor moves forwards and counts down when the conveyor moves backwards For information on finding the rotating direction see Rotating Direction on page 88 Connections for the second encoder shown above can only be used if the 2nd encoder is to be used as backup The 2 LEDs for e...

Page 93: ...at a diode is installed for each robot to prevent power from one of the robots which is on to be fed to a robot which is off If an external supply is used the internal supply must not be connected Connection for PNP encoder Connection for NPN encoder Encoder 24 VDC 0 Volt Robot 1 Robot 2 B 90 A 0 0V 24VDC Encoder Robot 1 Robot 2 B 90 A 0 0V 24VDC P_ENC1_A P_ENC1_ A P_ENC1_ B P_ENC1_ B 0 Volt 24 VD...

Page 94: ...on ex connection is used The switch can be installed on a bracket mounted on the conveyor Initiator Mounting If an initiator is used the initiator should be installed to detect the object directly or detecting the object suspension a flag on the suspension etc Normal Switch Mounting If a normal switch is used the switch arm must be in a perpendicular position in relation to the work object when th...

Page 95: ...tives Figure 44 Non ex sync switch connection alternatives If a normal switch photocell or initiator with a switch output is used the switch must be connected as shown in Alternative A If a switch with open collector transistor output is used the output from the switch should be connected as shown in Alternative B PNP or Alternative C NPN Ex Connection An ex sync switch must be connected via a tra...

Page 96: ...lations Observe that the hazardous area also includes areas just outside any spray booth opening as shown in Figure 42 Figure 45 Ex sync switch connection An ex type initiator may be used as alternative to a switch Such a switch device in conjunction with a transformer isolated barrier can be installed as shown in Alternative B Initiator Transformer isolated barrier Control cabinet Non hazardous a...

Page 97: ...arious external functions and systems to the controller Which connections that are to be made will depend on the installation Following external connections are described Digital I O Connection on page 98 Remote Panel Connections on page 99 Ethernet Communication on page 101 Pendant Connection on page 103 Cabinet Cooler Installation on page 105 Servo Disconnect on page 109 Home Position Switch on ...

Page 98: ...ctions Overview on page 42 Install 1 or 2 digital output loads in MIB board connector X8 pin 1 2 and 3 4 as shown in illustration above Max output current 100mA overload protection CAUTION If an inductive load is connected to an output a voltage suppression diode as shown in Figure 46 must be installed to protect the control electronics from voltage transients For information on tightening torque ...

Page 99: ...low Figure 47 Cabinet control panel remote panel connections All main control panel functions are available in connectors on the Safety Connection Board SCB Note The robot can not be operated without cabinet control panel or remote panel PLC installed Remote Panel Connections The following illustration shows the connections for remote panel Safety Interface Board SIB Remote panel X10 X5 X6 X2 X1 X...

Page 100: ...s supplied with the robot 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 X5 X6 X2 X1 X3 X13 X4 X8 X9 X10 X11 X12 X7 SCB 01 PNL_AUTO1 Safety_CH_Feed1 PNL_ES1_FEED PNL_ES1 PNL_ES2_FEED PNL_ES2 MON_ENA PNL_MOF PNL_MON PNL_MOF1 PNL_LMP_MON GND PNL_ES_RST PNL_HVOF1 PNL_HVON PNL_HVOF HV_PNL_HS PNL_LMP_PUR GND PNL_MAN1 PNL_MANFS1 PNL_AUTO2 Safety_CH_Feed2 PNL_MAN2 PNL_MANFS2 Emergency Stop Mo...

Page 101: ...side the control cabinet may be used for including the robot in an Ethernet network Figure 49 Ethernet communication concept Cable Information The cable used must be twisted pair Ethernet TPE or as defined in IEEE 802 3 10BASE T Local conditions such as electric environment determines how cable layout is to be performed The Ethernet connection has no termination for cable screen 10BASE T is a poin...

Page 102: ...ice purposes is connected to the cabinet service connection using a standard Ethernet cable The required crossing of the signals is performed by the internal cable Ethernet TPE Connector Ethernet TPE Connector Connector Signal name Description 1 TX Transmit data line 2 TX Transmit data line 3 RX Receive data line 4 NC Not connected 5 NC Not connected 6 RX Receive data line 7 NC Not connected 8 NC ...

Page 103: ...ng the emergency stop chain Following configurations are available Standard Connection The pendant is connected to the control cabinet via pendant connector X20 at the bottom front of the cabinet Figure 50 Pendant standard connection Hot Plug Connection The hot plug connection is an optional connector located on the side of the cabinet to enable connecting and disconnecting the pendant during oper...

Page 104: ...mon location is just inside the spray booth entrance door The connector is supplied with the extension cable Connect other end of cable to the pendant connector X20 at the bottom front of the cabinet or to an optional hot plug connector at the side of the cabinet Check that connector is connected to PE ground as described in IS Ground Connection on page 59 For information on the hot plug function ...

Page 105: ...t prepare the cut outs for the location of the cooler shown below For drawing of cut out and holes see manufacturer s documentation supplied with the cooler Figure 53 Cooler installation Cooler cable Drain hose connection Cooler unit Cabinet side wall Attachment nut and washer Electrical connection X79 Headless screw Drain water container Drain hose Cooler unit All dimensions in mm 280 550 153 Mai...

Page 106: ... the outside of the cabinet Important To minimize condensation it is important to set the internal temperature default 38 C not lower than actually needed To prevent condensation inside the control cabinet ensure that the control cabinet is a sealed enclosure especially watch cable inlets and door seals 7 Install door switch Cooling is switched off when control cabinet door is open 8 Install conne...

Page 107: ...ller trim panel onto display until it snaps into place 7 Re insert display into louvred grill 8 Install louvred grill on cooler LED Indicators The following provides a description of the LED indicators on the cooler controller trim panel 1 2 3 Description Remedy Source of fault line Green Power supply on OK Blinking green Door switch detects open control cabinet door In order to avoid condensation...

Page 108: ...troller After rectifying a high pressure alarm the cooler controller needs a manual reset 1 Remove cooler controller trim panel as described in Temperature Adjustment on page 107 2 Press reset button for at least 3 seconds 3 The red LED is extinguished 4 Reinstall the cooler controller trim panel as described in Temperature Adjustment on page 107 ...

Page 109: ...ors while all other functions of the controller are still powered The principle diagram is shown in following illustration Figure 55 Servo disconnect remote on terminal principle diagram The terminal XT5 is located at the bottom of the controller see Figure 17 Max cable length from control cabinet to external switch is 25 meter KM1 KM2 Optional servo disconnect 3 x 260 475VAC Transformer Servo Dri...

Page 110: ... manipulator axis 1 is in a determined home position The manipulator is equipped with a namur switch on axis 1 A relay is located in the control cabinet The principle diagram is shown in following illustration Figure 56 Home position switch principle diagram The relay with terminal X1 is located at the bottom of the controller see Figure 17 15 7 8 9 10 11 12 14 Control cabinet Manipulator 1 3 0V 2...

Page 111: ...e unit in section Purge Unit Installation on page 49 Figure 57 Purge unit location and connections 504 320 460 290 Input pressure on off valve Purging flushing pressure regulator Purging pressure gauge Maintenance pressure regulator Maintenance pressure gauge Purge sensor connector Purge valve connector located behind purge sensor connector Air supply connection Cables from control cabinet Flexibl...

Page 112: ...not be continuously exposed to solvent e g by laying the cables in a conduit which will drain solvent entering into it etc Figure 58 Purge unit connection box front view 1 Route the flexible hose s from the manipulator through the spray booth wall etc to the purge unit Note The lead through for the cable in the cabin wall must be made in accordance with the cabin safety regulations and ex regulati...

Page 113: ...op of the purge unit connection box Enter connector through hole and secure with 4 screws 6 Insert connectors from flexible hose s in receptacles for cables from control cabinet according to markings on connectors and Figure 58 7 The screened cables include a p clip at a stripped off section of the cable insulation Secure these p clips to the ground rail as shown in Figure 58 8 Secure loose wires ...

Page 114: ...ction provides information on how to connect the robot to the mains power including checking transformer wiring for correct voltage connections for service outlet etc Following connections are described Mains Power Connection on page 115 Transformer Wiring on page 117 Supply for Internal Light on page 118 Internal Supply for Service Outlet on page 119 24 VDC for External Use on page 120 ...

Page 115: ...ibed in Transformer Wiring on page 117 2 Check that the mains overload protection is set to correct current in accordance with supply voltage as shown below 3 Make sure that the mains switch is off Remove mains fuses for robot supply WARNING Make sure that mains fuses are removed before continuing 4 Route mains power cable as shown in Figure 59 Dismantle cable and install cable clamp For location ...

Page 116: ...s The mains cable must be min 3 x 2 5mm PE AWG 14 By mains 200V max length 85 meter by 2 5mm By mains 400V max length 174 meter by 2 5mm By longer supply lines cable area must be increased or fuse size reduced 6 Install mains fuses Important Due to the autotransformer drive system mains filter configuration in the IRC5P controller an imbalance between the supply phases to the system can occur duri...

Page 117: ...t front door 2 Locate the transformer terminal board located on the back wall inside the controller as shown in Controller Connections Overview on page 42 3 Check connection of transformer as shown in Figure 60 4 If wiring is not correct move wires for phase 1 2 and 3 to correct terminal For information on tightening torque for terminal connections see Tightening Torques on page 216 5 Check that s...

Page 118: ... lower left bottom of the control cabinet as shown in Figure 17 The AC power is connected to the rectifier via a door switch The light is switched on when the cabinet door is open Figure 61 115 230 VAC terminal board Optionally the power may be connected to the control cabinet internal power supply which means that the light can only be switched on when the control cabinet is switched on For infor...

Page 119: ...ommon Neutral Specification Connections AC supply is available for customer on the transformer terminal board as shown in the illustration below Figure 62 115 230 VAC terminals For information on tightening torque for terminal connections see Tightening Torques on page 216 Voltage 115 or 230 V Permitted customer load Max 700 VA Fuse size 3 15 A 230 V 6 3 A 115 V Neutral Supply overload protection ...

Page 120: ... cases When more power is needed than can be supplied by the internal supply When the emergency stop circuits are to be independent of whether or not the robot is powered When there is a risk that major interferences can be carried over into the internal 24V supply An external supply is recommended to make use of the advantages offered by the galvanic insulation on the I O units The neutral wire i...

Page 121: ...er Connections exceeded For example a neutral wire must be connected to the chassis earth of the controller or some other common earthing point External supply must confirm to following specifications Potential difference to chassis earth Max 60 V continuous Permitted supply voltage 19 35 V including ripple ...

Page 122: ...luding Activities Description The controller is now installed and all required connections correctly made Before continuing the installation activities such as installing the manipulator and starting up the system all connections should be verified as required and the Installation Checklist supplied with the robot should be filled in ...

Page 123: ...rocedures Read the Safety Manual before performing any service work WARNING No maintenance work must be performed on the controller before the safety guidelines in the Safety Manual have been read and understood Work must only be performed by skilled personnel with the proper training General Considerations The prime objective of any preventive maintenance program is to ensure maximum system avail...

Page 124: ...1 General Maintenance on page 125 Daily 1 2 Clean Replace Filter on page 126 500 hours 1 3 Replace the measuring system battery as described in Replacement of Measuring System Battery on page 167 For more information see Checking the Measuring System Battery on page 127 7 000 hours 2 4 Replace fan units in control cabinet as described in Replacement of Door Fan Unit on page 135 Replacement of Comp...

Page 125: ...e air filter is dirty Important The controller front door must always be kept closed when no work is being performed inside the controller Cleaning the Pendant The pendant must be cleaned as often as required Although the panel film is resistant against most solvents strong solvents such as acetone etc should be avoided If practical pendant should be disconnected and taken to a clean place when no...

Page 126: ...ter holder up and out 3 Remove old filter from filter holder 4 Insert new filter in filter holder As an alternative to replacing the filter the filter may be cleaned Clean the filter three or four times in 30 40 C water with washing up detergent The filter must not be wrung out but should be allowed to dry on a flat surface Alternatively the filter can be blown clean with compressed air from the c...

Page 127: ...g Life time after this message is approx 1800 hours The battery is only used when the control cabinet is switched off The battery service life time is approx 7000 hours It is recommended to replace the battery when the message appears For information on how to replace the battery see Replacement of Measuring System Battery on page 167 Note If the control cabinet controls a CBS unit in addition to ...

Page 128: ...lay 2 Remove filter from louvered grill if installed Clean filter with a vacuum cleaner or replace as required 3 Remove the external circuit fan by removing 4 e a screws 65 1 4 Remove the fan 65 2 5 Disconnect the fan connectors 65 3 6 Remove the cover by removing 4 e a screws 65 4 7 Push back the display cable through the cable gland 8 Remove the cover from the cooler enclosure 9 Remove the earth...

Page 129: ...re for refitting At the start of each procedure a reference list shows information located other places in the manual than in the procedure If you want to print out a procedure you should also print the information referred to under reference to get all information you need to perform the repair operation The manual describes the type of service work that can be carried out by the Customer s own s...

Page 130: ...e Operator s Manual IRC5P ESD Precautions Electronic devices are sensitive to static electricity If handled incorrectly the unit may be permanently damaged Following precautions should be taken at all times when handling sensitive electronic units ALWAYS keep electronic units protected in static shielded plastic bags when not installed in the robot These bags are made from a special conductive mat...

Page 131: ...panel board WARNING No repair work must be performed on the robot before the safety regulations in Safety on page 13 have been read and understood 1 Turn the electrical disconnect switch off and lock switch in off position WARNING Make sure that the mains switch is off and locked in off position before continuing Also make sure that possible other connected systems are off 2 Open controller front ...

Page 132: ...n in the illustration below Figure 67 Panel board location of switches and lamps Refitting The procedure describes how to re install the control panel board WARNING Refitting activities must only be performed when controller is switched off and all safety precautions under Removal have been read 1 If a panel button was removed install new button and tighten attachment screw 2 Connect mode selector...

Page 133: ...on the robot before the safety regulations in Safety on page 13 have been read and understood CAUTION The unit is sensitive to ESD Before handling the unit please observe the safety information in ESD Precautions on page 130 1 Turn the electrical disconnect switch off and lock switch in off position WARNING Make sure that the mains switch is off and locked in off position before continuing Also ma...

Page 134: ...nstall the system LED board WARNING Refitting activities must only be performed when controller is switched off and all safety precautions under Removal have been read 1 Place the board in position over the attachment holes Make sure the orientation of the board is correct 2 Install attachment screws and tighten 3 Insert connectors 4 Close controller front door ...

Page 135: ...e the fan unit on the front door WARNING No repair work must be performed on the robot before the safety regulations in Safety on page 13 have been read and understood 1 Turn the electrical disconnect switch off and lock switch in off position WARNING Make sure that the mains switch is off and locked in off position before continuing Also make sure that possible other connected systems are off 2 O...

Page 136: ... The procedure describes how to re install the fan unit WARNING Refitting activities must only be performed when controller is switched off and all safety precautions under Removal have been read 1 Place the fan unit in position over the attachment screws 2 Slide the unit into position and tighten attachment screws 3 Insert connector 4 Secure cable with a new cable strap 5 Close controller front d...

Page 137: ... any of the above mentioned units Note When replacing the PIB board the key chip must be moved to the new PIB board For information on the key chip see Unit Description IRC5P section Paint Control Module Paint Interface Board PIB WARNING No repair work must be performed on the robot before the safety regulations in Safety on page 13 have been read and understood CAUTION The unit is sensitive to ES...

Page 138: ...or the axis computer the two screws on the left must be fully removed 5 Remove unit from controller Refitting The procedure describes how to re install the board WARNING Refitting activities must only be performed when controller is switched off and all safety precautions under Removal have been read Note Make sure that the new unit is of the same type as the old unit For information on the differ...

Page 139: ...NING No repair work must be performed on the robot before the safety regulations in Safety on page 13 have been read and understood CAUTION The unit is sensitive to ESD Before handling the unit please observe the safety information in ESD Precautions on page 130 1 Turn the electrical disconnect switch off and lock switch in off position WARNING Make sure that the mains switch is off and locked in ...

Page 140: ...ly by carefully moving board assembly out Note The TIB board is inserted in the rear of the pendant connector 71 2 and may therefore be a bit hard to remove Refitting The procedure describes how to re install the TIB board WARNING Refitting activities must only be performed when controller is switched off and all safety precautions under Removal have been read 1 Place new TIB board assembly in pos...

Page 141: ...move an I O unit WARNING No repair work must be performed on the robot before the safety regulations in Safety on page 13 have been read and understood CAUTION The unit is sensitive to ESD Before handling the unit please observe the safety information in ESD Precautions on page 130 1 Turn the electrical disconnect switch off and lock switch in off position WARNING Make sure that the mains switch i...

Page 142: ...screwdriver until the upper claw 72 4 that holds the unit to the rail is released 6 With the upper claw released tip the unit away from the mounting rail 72 5 and remove it Refitting The procedure describes how to re install the I O unit WARNING Refitting activities must only be performed when controller is switched off and all safety precautions under Removal have been read 1 Hook the unit back o...

Page 143: ...of internal components the computer unit cover needs to be removed This is performed by removing 4 attachment screws 73 4 lift off the cover 73 3 and disconnect the fan connector 73 6 WARNING No repair work must be performed on the robot before the safety regulations in Safety on page 13 have been read and understood CAUTION The unit is sensitive to ESD Before handling the unit please observe the ...

Page 144: ... unit up and out 7 If further activities are to be performed such as replacing a PCI card place the computer unit on a clean work bench and continue to the relevant procedure Important When placing the computer unit on a table etc pay attention to the attachment hooks to avoid bending the hooks or scratching the table Refitting The procedure describes how to re install the computer unit WARNING Re...

Page 145: ... board from the computer unit WARNING No repair work must be performed on the robot before the safety regulations in Safety on page 13 have been read and understood CAUTION The unit is sensitive to ESD Before handling the unit please observe the safety information in ESD Precautions on page 130 1 Turn the electrical disconnect switch off and lock switch in off position WARNING Make sure that the m...

Page 146: ...cedure describes how to re install the computer unit mother board WARNING Refitting activities must only be performed when controller is switched off and all safety precautions under Removal have been read 1 Gently lift the mother board out of the ESD safe bag and place it into position in the computer module Note Be careful not to bend the LEDs when inserting the board 2 Secure the board with the...

Page 147: ...emove a PCI board WARNING No repair work must be performed on the robot before the safety regulations in Safety on page 13 have been read and understood CAUTION The unit is sensitive to ESD Before handling the unit please observe the safety information in ESD Precautions on page 130 1 Turn the electrical disconnect switch off and lock switch in off position WARNING Make sure that the mains switch ...

Page 148: ...e board in an ESD safe bag or similar Refitting The procedure describes how to re install the computer unit power supply WARNING Refitting activities must only be performed when controller is switched off and all safety precautions under Removal have been read 1 Fit the card in position by pushing the card into the socket on the mother board Secure it with its attachment screw 2 Connect any additi...

Page 149: ...st be performed on the robot before the safety regulations in Safety on page 13 have been read and understood CAUTION The unit is sensitive to ESD Before handling the unit please observe the safety information in ESD Precautions on page 130 1 Turn the electrical disconnect switch off and lock switch in off position WARNING Make sure that the mains switch is off and locked in off position before co...

Page 150: ...tting The procedure describes how to re install the fieldbus adapter in the computer unit WARNING Refitting activities must only be performed when controller is switched off and all safety precautions under Removal have been read 1 Grip the fieldbus adapter around the edges CAUTION Make sure that the adapter is pushed straight onto the rails 2 Fit the fieldbus adapter in position by pushing the fi...

Page 151: ...required Removal The procedure describes how to remove the compact flash from the computer unit WARNING No repair work must be performed on the robot before the safety regulations in Safety on page 13 have been read and understood CAUTION The unit is sensitive to ESD Before handling the unit please observe the safety information in ESD Precautions on page 130 1 Turn the electrical disconnect switc...

Page 152: ... off and all safety precautions under Removal have been read 1 Carefully position the compact flash card in the guides which are located at the inner end of the compact flash slot Important Be careful when inserting the compact flash If you loose the grip the card may fall down inside the computer unit 2 Gently glide the card into position against the connector CAUTION Be careful when performing n...

Page 153: ...he safety regulations in Safety on page 13 have been read and understood CAUTION The unit is sensitive to ESD Before handling the unit please observe the safety information in ESD Precautions on page 130 1 Turn the electrical disconnect switch off and lock switch in off position WARNING Make sure that the mains switch is off and locked in off position before continuing Also make sure that possible...

Page 154: ...t WARNING Refitting activities must only be performed when controller is switched off and all safety precautions under Removal have been read 1 Install new fan unit 2 Refit the attachment screw 3 Refit the computer unit cover by connecting fan unit connector placing cover in position and installing attachment screws 4 Refit the computer unit as described in procedure Replacement of Computer Unit o...

Page 155: ...safety regulations in Safety on page 13 have been read and understood CAUTION The unit is sensitive to ESD Before handling the unit please observe the safety information in ESD Precautions on page 130 1 Turn the electrical disconnect switch off and lock switch in off position WARNING Make sure that the mains switch is off and locked in off position before continuing Also make sure that possible ot...

Page 156: ...nel Refitting The procedure describes how to re install a drive unit or the rectifier unit WARNING Refitting activities must only be performed when controller is switched off and all safety precautions under Removal have been read Note Make sure that the new unit is of the same type as the old unit For information on the different types used see Unit Description IRC5P 1 Fit the new unit in its int...

Page 157: ...erences For information on location of the individual drive units drive unit types etc see Unit Description IRC5P Tools and Items Hand tools Removal The procedure describes how to remove a drive unit the rectifier unit or the capacitor 1 Motor drive unit assembly 8 Motor drive 6 pack attachment screws 2 Pump drive unit assembly 9 Motor drive 3 pack attachment screws 3 Capacitor unit 10 Motor drive...

Page 158: ...the unit that shall be removed 4 Remove busbar 79 11 between units 5 Unscrew attachment screws for drive unit 79 8 9 14 rectifier 79 6 or capacitor 79 4 6 Remove unit WARNING Capacitor or Capacitor Rectifier units depending on robot type may contain residual power These units must only be opened by qualified personnel Refitting The procedure describes how to re install a drive unit the rectifier u...

Page 159: ... on the robot before the safety regulations in Safety on page 13 have been read and understood 1 Turn the electrical disconnect switch off and lock switch in off position WARNING Make sure that the mains switch is off and locked in off position before continuing Also make sure that possible other connected systems are off 2 Locate fan unit servo 81 1 located on the top of the cabinet rear housing ...

Page 160: ...es how to re install the fan unit servo WARNING Refitting activities must only be performed when controller is switched off and all safety precautions under Removal have been read 1 Insert fan unit connector 2 Slide fan unit into position Make sure that the unit is installed in correct orientation as shown in Figure 81 3 Install attachment screws and tighten ...

Page 161: ...brake resistor bleeders WARNING No repair work must be performed on the robot before the safety regulations in Safety on page 13 have been read and understood 1 Turn the electrical disconnect switch off and lock switch in off position WARNING Make sure that the mains switch is off and locked in off position before continuing Also make sure that possible other connected systems are off 2 Remove ser...

Page 162: ...using a pin extraction tool or a small screwdriver 7 Pull wires through hole in cabinet back wall 8 Loosen bleeder attachment screws 82 3 a little 9 Lift bleeder up and out 10 Remove bleeder Refitting The procedure describes how to re install the brake resistor bleeders WARNING Refitting activities must only be performed when controller is switched off and all safety precautions under Removal have...

Page 163: ...the safety regulations in Safety on page 13 have been read and understood CAUTION The unit is sensitive to ESD Before handling the unit please observe the safety information in ESD Precautions on page 130 1 Turn the electrical disconnect switch off and lock switch in off position WARNING Make sure that the mains switch is off and locked in off position before continuing Also make sure that possibl...

Page 164: ...off and all safety precautions under Removal have been read 1 Lift transformer into position on the cabinet rear bottom plate Be careful not to damage terminal board and overload protection while guiding through hole in cabinet back wall 2 Insert 2 transformer attachment screws and tighten 3 Insert 6 transformer bracket attachment screws Tighten screws 4 Connect electric wires to terminal board an...

Page 165: ...on the choke filter see Unit Description IRC5P Tools and Items Hand tools Removal The procedure describes how to remove the choke filter unit WARNING No repair work must be performed on the robot before the safety regulations in Safety on page 13 have been read and understood 1 Turn the electrical disconnect switch off and lock switch in off position WARNING Make sure that the mains switch is off ...

Page 166: ...screws 84 4 securing the unit to the cabinet bottom plate 6 Remove choke filter Refitting The procedure describes how to re install the choke filter unit WARNING Refitting activities must only be performed when controller is switched off and all safety precautions under Removal have been read 1 Lift choke filter into position on the cabinet rear bottom plate 2 Insert 2 filter attachment screws and...

Page 167: ... The procedure describes how to remove the measuring system battery Note Before performing this procedure it is recommended to place the robot into calibration position markings on the axes WARNING No repair work must be performed on the robot before the safety regulations in Safety on page 13 have been read and understood CAUTION The unit is sensitive to ESD Before handling the unit please observ...

Page 168: ...If a strap is used to secure the battery remove strap 5 Lift the old battery 85 2 out of the battery holder 85 4 Refitting The procedure describes how to re install the measuring system battery WARNING Refitting activities must only be performed when controller is switched off and all safety precautions under Removal have been read 1 Place the new battery in the holder 2 Connect the battery connec...

Page 169: ...er is divided into 4 sections as follows General description of trouble shooting routines and valuable hints on how to perform trouble shooting Listing of some relevant fault symptoms and malfunctions Trouble Shooting instructions for some individual units Description of the LED indicators on the controller front For description of the LED indicators on the separate units inside the controller see...

Page 170: ...lt log as specified in section Keep Track of History on page 173 Split the Fault Chain When trouble shooting any system a good practice is to split the event chain in two This means Identify the complete chain of events Decide and measure the expected value at the middle of the chain Use this to determine in which half the fault is caused Split this half into two new halves etc Finally a single co...

Page 171: ...ircuit Diagram The complete electrical circuitry of the controller and manipulator is available on the DVD ROM shipped with the robot These circuit diagrams contain a lot of useful or even essential information to a trained trouble shooter Read the Logs The event logs contain lots of information about operations and malfunctions detected by the system For information on operating the logs see the ...

Page 172: ...he manipulator and controller at hand Test the system after replacing to see if the problem has been solved If replacing several units at once It is impossible to determine which of the units was causing the fault It greatly complicates ordering a new spare part It may introduce new faults to the system Take a Look Around Often the cause may be evident by visual inspection In the area of the unit ...

Page 173: ...r occurs keep track of the last operations done by the robot Check Up the History Make sure you always consult the historical log if it is used Also remember to consult the person who was observing the problem At What Stage did the Fault Occur What to look for during trouble shooting depends greatly on when the fault occurred Was the robot just freshly installed Was it recently repaired The table ...

Page 174: ...ibility problems for instance a specific circuit board may work well with one release but not with another Since the robot system is complex and since the system often works in connection with a large number of additional equipment keeping track of each hardware software combination is difficult Technical Service Information Each software release is accompanied by a Technical Service Information T...

Page 175: ...ribed in section Start Up Failures on page 177 The system does not start or displays irrational behavior during startup These faults are described in section Start Up Failures on page 177 A normal start up sequence is described in section Normal Start Up Sequence on page 176 Indications on the LED panel indicators on the front of the control cabinet The significance of each LED is described in cha...

Page 176: ...art up procedure see Operator s Manual IRC5P Installation and Commissioning Switch on Mains Power Start Up Sequence When the mains power switch is switched on power is supplied to the robot system 1 The robot performs its self test on both the hardware and software The LEDs are flashing alternating red and green 2 The Enable PIB LED is blinking red during loading of the FPGA 3 The SPI LED is red d...

Page 177: ...nnection on page 115 2 Make sure the mains switch is switched on 3 Make sure the mains power supply to the system is present and within specified limits The installation documentation may provide this as well as other vital information 4 Make sure that the supply voltages from the PDB board are present and within the specified limits If required trouble shoot PDB described in Trouble Shooting Powe...

Page 178: ...ns power supply in the shop is working and that the voltage level matches that of the controller requirement The installation documentation may provide this as well as other vital information 2 Make sure the main transformer has been correctly connected for the mains voltage level at hand How to connect the transformer is found under Mains Power Connection on page 115 3 Make sure the mains overloa...

Page 179: ...AIT instructions Use only short WAIT times to avoid slowing the program down unnecessarily Suitable places to add WAIT instructions may be In a WHILE FOR GOTO loop preferably at the end close to the ENDWHILE ENDFOR etc part of the instruction In an auto looping background task ref Rapid OverView Multitasking 2 Make sure the poll rate value for each I O board is not too low These values are changed...

Page 180: ... The pendant is not connected to the controller The cable from the controller is damaged The cable connector is damaged The pendant is faulty Pendant power supply from controller is faulty Recommended Actions Step Action Comment 1 Make sure the system is switched on and that the pendant is connected to the controller How to connect the pendant to the controller is described in Pendant Connection o...

Page 181: ... Recommended Actions Step Action Comment 1 Make sure the pendant has been correctly connected to the controller How to connect the pendant is described in Pendant Connection on page 103 2 Make sure the power supply is OK and communication lines are OK Check power supply system and signal lines 3 Check LED indicators on the front panel For description see LED Indicator Panel on page 197 4 Make sure...

Page 182: ...ses The symptom may be caused by Internal manipulator cabling not correctly performed Causes may be faulty connection of connectors cable loops too tight causing the cabling to get strained during manipulator movements cable insulation worn or damaged by rubbing short circuiting signals to ground Recommended Actions Step Action Comment 1 Inspect all internal manipulator cabling especially all cabl...

Page 183: ...work Probable Causes The symptom may be caused by the causes are listed in order of probability Blown fuse FU2 230VAC or FU3 115VAC Mains power supply loss Transformers incorrectly connected Recommended Actions Step Action Comment 1 Make sure the fuse is not blown Make sure any equipment connected to the service outlet does not consume too much power causing the fuse to blow 2 Make sure the power ...

Page 184: ...icks are damaged Recommended Actions Step Action Comment 1 Check that the system has been switched on Ref Operator s Manual IRC5P 2 Check that Key Switch is in Manual Reduced Speed Mode If NOT proceed as described in the Operator s Manual IRC5P 3 Check that all Emergency stop buttons are released and then Press Motor On button to close Run Chain 4 Check that Live Handle is operated properly Ref Op...

Page 185: ...t most often occurs due to a lack of compatibility between hardware and software Consequences Step Action Comment 1 Check the event log for a message specifying which unit failed For information on event log messages see Operating Manual Trouble Shooting Event Log Messages 2 Was the relevant unit recently replaced If YES make sure the versions of the old and new unit is identical If NOT check the ...

Page 186: ...ox damaged often causing noise Bearings damaged or worn especially if the path inconsistency is coupled with clicking or grinding noises from one or more bearings The brakes may not be releasing correctly Recommended Actions Step Action Comment 1 Locate a faulty bearing by tracking the noise Replace faulty bearing See Product Manual Manipulator 2 Locate the faulty motor by tracking the noise Study...

Page 187: ...type may be connected to the controller Recommended Actions Step Action Comment 1 Make sure the robot Tool is correctly defined How to define the TCP is described in the Operator s Manual IRC5P 2 Check the revolution counter If required update revolution counter as described in Operator s Manual IRC5P 3 If required re calibrate the robot axes Make sure the robot is calibrated as described in Opera...

Page 188: ...ity Leaking seal between gearbox and motor Gearbox overfilled with oil Gearbox oil too hot Recommended Actions CAUTION Parts of the manipulator may be hot and care must be taken to avoid touching these components before they have been allowed to cool down Step Action Comment 1 Inspect all seals and gaskets between motor and gearbox The different manipulator models use different types of seals Repl...

Page 189: ... avoid touching these components before they have been allowed to cool down Step Action Comment 1 Determine which bearing is causing the noise 2 Make sure the bearing has sufficient lubrication and is not contaminated See Product Manual Manipulator 3 If possible disassemble the joint and measure the clearance See Product Manual Manipulator 4 Bearings inside motors are not to be replaced individual...

Page 190: ...ng equipment Possible Causes The symptom may be caused by Faulty brake Grease or oil on brakes Brakes worn causing dust to be accumulated on the brake discs Note It is not normal for the brakes to become worn as they shall become engaged only when the motor is not turning Exception Emergency stop Therefore do not use Emergency stop for normal stops Recommended Actions Step Action Comment 1 Determi...

Page 191: ...formation see relevant manipulator board in Unit Description IRC5P 2 Make sure the RUN Chain is closed Check run chain For information see Robot Safety System Connections on page 64 3 Try to release brakes manually If just one of the brakes malfunctions the brake at hand is probably faulty and will have to be replaced If none of the brakes work there is probably no 24V_BRAKE power available For in...

Page 192: ...ment 1 If the pendant is completely dead proceed as detailed in section Pendant Dead on page 180 2 If the pendant starts but does not operate correctly proceed as detailed in section Pendant does not Communicate on page 181 3 If the pendant starts seems to operate but displays erratic event messages proceed as detailed in section Erratic Event Messages on Pendant on page 182 4 Check the cable for ...

Page 193: ...e LED indicators see Power Distribution Board PDB in Unit Description IRC5P 2 Disconnect the output connector of the power supply unit 3 Measure the output voltage of the unit If no voltage or an incorrect voltage is detected proceed with next step 4 Measure the input voltage If the input voltage is correct the power supply unit may be faulty 5 If required disconnect the loads from the power suppl...

Page 194: ...P 8 4 3 Trouble Shooting Communications Overview This section details how to trouble shoot data communication between the different units in the controller Trouble Shooting Procedure Step Action Comment 1 Faulty cables e g send and receive signals are mixed up 2 Transfer rates baud rates 3 Data widths that are incorrectly set ...

Page 195: ...dual unit in Unit Description IRC5P Distributed I O Step Action Comment 1 Check that the current I O signal has the desired status using the I O menu on the pendant display 2 Check the I O unit s LED for the current input or output If the output LED is not lit check that the 24V I O power supply is OK 3 Check on all connectors and cabling from the I O unit to the process connection 4 Make sure the...

Page 196: ...rgency stop and Enable chains Make sure all connectors are connected securely 2 Check that grounding and shielding are properly done 3 Check if any LED indicator may give some clue to the problem The significance of all LED indicators are specified under LED Indicator Panel on page 197 and under the different boards and units in Unit Description IRC5P 4 Check the messages in the event log Sometime...

Page 197: ...p Robot 1 Process 2 1 2 2 Paint Enable Emy Stop Panel Emy Stop Pendant Emy Stop External Emy Stop Chain Mode Stop Enabling Device Enable Main Enable Axis Enable PIB Enable SIB Enable MIB Enable Manipulator 1 Enable Manipulator 2 2 Ch Monitoring Power status Temp Cabinet Enable Chain Closed Overpressure Pressurized Min Flow Purge Timer Process Status System Status Cooling Fan HV Chain SPI Int Ext D...

Page 198: ...r On button to reset Run Chain If not OK proceed below Check emy stop chain 1 and or 2 from main panel switch to pendant switch Check pendant cable and connector If the pendant is not connected a dummy connector must be installed in its place Check I S barriers TIB board and wiring Check SIB board for malfunction Replace as required Emy Stop External Chain 1 2 Green OK Off External emergency stop ...

Page 199: ...bling device is depressed Check that mode selector is in manual mode Check pendant cable and connector Check I S barriers TIB board and wiring Check SIB board for malfunction Replace as required Check run chain 1 and or 2 from 24VDC supply via mode selector to pendant enabling device General Mode Stop Chain 1 2 Green OK Off General mode stop is activated The run chain is broken at the general mode...

Page 200: ...IB Description Source of fault Remedy Paint Enable Chain 1 2 Green Chain closed Blinking Green Process interlock open cabin interlock closed Blinking Red Divergency in process interlock chain Off Cabin interlock chain is broken The cabin interlock chain is broken This chain includes a safety switch on the cabin door and a cabin interlock switch for the cabin ventilation to disable the paint contro...

Page 201: ...ted I O CAN2 is normally not used If used check CAN bus from PIB to external I O nodes SPI Int Ext Green OK Red During SPI initialization SPI bus communication between PIB and SIB MIB SPI Int and between PIB and external I O units SPI Ext If LED is Off blinking green red or blinking red check That nodes are initialized Cables and connections PIB board and units connected to SPI bus For more inform...

Page 202: ... Enable Manipulator 2 Same as Enable Manipulator 1 but for 2nd manipulator such as CBS 2 Ch Monitoring Green OK Blinking Red Failure divergency in switches and or relays in safety chain Check Run Chain LEDs for divergency Check safety chain switches and relays for malfunction Check wiring and connections for Emy Stop buttons Safety element not tested after divergency failure Power Status Green OK ...

Page 203: ...ply Check purge sensor Check cables and wiring Check LEDs Purging P1 and P2 should be lit Note Indicator will be red in a short period while pressure is being established Purge Timer Blinking Green Purge sequence in progress Off Purge sequence not started or sequence completed Indicates status of purge sequence Check purge LEDs Overpressure Pressurized and Min Flow should be lit Process Status Gre...

Page 204: ...USER 4 3 user definable LEDs These LEDs can be specified by the user in the software Display Valid Green OK System indicator board ALED is active Off ALED board not active Note that LED is blinking red green during initialization until communication with PIB is started Check communication cable between PIB and ALED Try to reset board by momentary disconnecting power connector to ALED Check ALED bo...

Page 205: ...is 2 arm lower part IRB 5400 IRB 540 IRB 580 Foot unit IRB 5500 Foot unit base arm assembly IRB 52 Foot unit base inner arm IRB 5300 Steel Gears screws base frame etc All robot types Foot unit axis 7 arm axis 8 arm IRB 5500 w 2 axis swing arm Samarium Cobalt Brakes motors All robot types Plastic rubber PVC Cables connectors drive belts etc All robot types Oil grease Gearboxes All robot types Alumi...

Page 206: ...ispose of oil and grease near lakes ponds ditches down drains or onto soil Incineration must be carried out under controlled conditions in accordance with local regulations Also note that Spills may form a film on water surfaces causing damage to organisms Oxygen transfer could also be impaired Spillage may penetrate the soil causing ground water contamination Balancing system If the robot include...

Page 207: ...e Information Product Manual Control Cabinet IRC5P 3HNA009834 001 en Rev 06 207 10 Reference Information General This chapter includes information complementing the more specific information in the product manual ...

Page 208: ...l Signals Shielded cable Measuring Signals Shielded cable with twisted pair conductors Data Communication Signals Shielded cable with twisted pair conductors A specific cable should be used for Gateway field bus connections and Ethernet CAN bus with DeviceNet for Distributed I O units Thin cable according to DeviceNet specification release 1 2 must be used The cable is shielded and has four conduc...

Page 209: ...lays increases after neutralization especially if a diode is connected across the coil Varistors give shorter turn off times Neutralizing the coils lengthens the life of the switches that control them Figure 87 Examples on how peripheral equipment can be neutralized 24 VDC 0 Volt 24 V DC or AC voltage 0 Volt R C The diode is to be dimensioned for the same current as the relay coil and a voltage of...

Page 210: ...protection sleeve is installed on the two wire ends The cable screen must be connected at the lead through in the cabinet Ref Clamping Cables on page 213 Connections to Spring Terminals The robot may include terminal boards with spring connection of wires with area between 0 25 1 5mm Only one wire can be connected to each of these terminals The cable is released from the connection by inserting a ...

Page 211: ... cables In the following you will find information and hints on how proper bonding can be obtained For more information on protecting of signal cables etc books describing the subject are available on the market Bonding Connections When the robot is installed in accordance with the description in this manual all components of the robot system control cabinet manipulator purge unit and possible ext...

Page 212: ...ections in the robot system Note The bonding wire may be omitted The use of this wire depends on the size of the components the amount of noise which can be induced in the component casing the distance to the component the signals sensitivity to noise and present noise in the installation etc External cabinet junction box etc Bonding wire Factory mains ground connection Control cabinet Screened ca...

Page 213: ...gure 89 center For the motor signal cable connected to X11 and X12 it must be observed that both the outer screen for the motor cable and the inner screen for the signal cable must be secured under the clamp Ref Figure 89 inset Method C Cables for sensitive signals Cable for extra sensitive signals such as analog signals must be grounded at the component where it is connected in addition to the gr...

Page 214: ...s shown in Figure 90 example 2 If the cable is routed and terminated in a junction box etc and the junction box has a good bonding connection the screens for both cables must be bonded at this point Example 3 If the cable is terminated in a junction box or other unit where a good bonding is not available the screens of the 2 cables must be connected as shown in Figure 90 example 3 but not connecte...

Page 215: ...noise is present in the situations shown in Figure 90 example 2 and 3 a ceramic capacitor of e g 0 22µF can be installed between the screen and chassis as shown in example 3 Cables of different types such as signal cables and power cables must not be routed together as the power cables may introduce noise in the signal cable If the bonding has been performed according to the general guidelines giv...

Page 216: ... 12 9 quality Torques apply to lightly lubricated screws Torque Tables for Screws with Hexagon Socket Heads The table below shows tightening torques for screws used Torque Table for Slotted or Cross Recessed Head The table below shows tightening torques to be used for electrical connections terminal board screws etc Table 1 Screw quality Nominal Diameter 8 8 Nm 12 9 Nm M4 2 9 4 9 M5 5 9 10 0 M6 9 ...

Page 217: ...ification Page Preface A009834 9 1 Introduction T02606 Rev 02 11 2 Safety T02607 Rev 01 13 3 System Description T02644 Rev 06 15 4 Technical Specifications T02724 Rev 07 31 5 Installation and commissioning T02608 Rev 07 39 6 Preventive Maintenance T02609 Rev 05 123 7 Repair T02610 Rev 04 129 8 Trouble Shooting T02604 Rev 05 169 9 Decommissioning T02611 Rev 05 205 10 Reference Information T02612 Re...

Page 218: ...218 3HNA009834 001 en Rev 06 Product Manual Control Cabinet IRC5P Manual Status ...

Page 219: ...T0260842 wmf 79 T0260820 wmf 84 T0260821 wmf 85 T0260822 wmf 87 T0260826 wmf 90 T0260827 wmf 91 T0260828 wmf 92 T0260829 wmf 93 T0260830 wmf 94 T0260831 wmf 94 T0260832 wmf 95 T0260833 wmf 96 T0260834 wmf 98 T0260835 wmf 99 T0260837 wmf 100 T0260836 wmf 101 T0260838 wmf 102 T0260839 wmf 103 T0260846 wmf 103 T0260844 wmf 104 T0260840 wmf 105 T0260845 wmf 107 T0260847 JPG 300 dpi 107 T0260848 JPG 30...

Page 220: ...220 3HNA009834 001 en Rev 06 Product Manual Control Cabinet IRC5P Pg Illustration Pg Illustration Pg Illustration List of Imported Graphics ...

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