IRC5-IRC5 Product Reference Manual 3HAC021313-001_part2_revA_en
Short Description
....
Description
Product manual (part 2 of 2), reference information Robot Controller IRC5 M2004
Product manual (part 2 of 2), reference information IRC5 M2004 Document ID: 3HAC021313-001 Revision: A
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 ABB All right reserved. ABB Automation Technologies AB Robotics SE-721 68 Västerås Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1 Reference information, IRC5
7
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.6 Standard toolkit, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.7 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2 Spare Parts
17
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.2 Spare Parts IRC5, Control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.3 Spare Parts IRC5, Drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 3 Circuit Diagram
23
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3HAC021313-001
3
Overview
Overview About This Manual This manual contains reference information for all procedures described in the Product manual procedures. Usage This manual should be used during: operation, installation... •
installation
•
maintenance work
•
repair work.
Who Should Read This Manual? This manual is intended for: •
installation personnel
•
maintenance personnel
•
repair personnel.
Prerequisites The reader should... •
be a trained maintenance/repair craftsman
•
have the required knowledge of mechanical and electrical installation/maintenance/ repair work.
Organization of Chapters The manual is organized in the following chapters: Chapter
Contents
Reference information
Useful information when performing installation, maintenance or repair work (lists of necessary tools, reference documents, safety standards).
Spare part list
List of controller spare parts.
Circuit diagram
Circuit Diagram of the controller.
References See section document references. Revisions
4
Revision
Description
-
First edition
A
3HAC021313-001
Product documentation, M2004
Product documentation, M2004 General The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems. Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures •
Safety information
•
Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software)
•
Maintenance (descriptions of all required preventive maintenance procedures including intervals)
•
Repair (descriptions of all recommended repair procedures including spare parts)
•
Additional procedures, if any (calibration, decommissioning)
Product manual, reference information •
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
RobotWare manuals The following manuals describe the robot software in general and contain relevant reference information: •
RAPID Overview: An overview of the RAPID programming language.
•
RAPID reference manual part 1: Description of all RAPID instructions.
•
RAPID reference manual part 2: Description of all RAPID functions and data types.
•
Technical reference manual - System parameters: Description of system parameters and configuration workflows.
Application manuals Specific applications (e.g. software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about:
3HAC021313-001
•
The purpose of the application (what it does and when it is useful)
•
What is included (e.g. cables, I/O boards, RAPID instructions, system parameters) A
5
Product documentation, M2004
•
How to use the application
•
Examples of how to use the application
Operator’s manuals This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters. The group of manuals include: •
Operator’s manual - IRC5 with FlexPendant
•
Operator’s manual - RobotStudioOnline
•
Trouble shooting Manual for the controller and robot
Miscellaneous A number of manuals provide generic descriptions of the robot and robot system. These include: •
6
Robot fundamentals (describing the fundamental aspects, functions, concept and similar, of a robot system to provide a basic understanding of the robot system)
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3HAC021313-001
1 Reference information, IRC5 1.1. Introduction
1 Reference information, IRC5 1.1. Introduction General This chapter includes general information, complementing the more specific information in the following chapters.
3HAC021313-001
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7
1 Reference information, IRC5 1.2. Applicable Safety Standards
1.2. Applicable Safety Standards Standards, general The robot is designed in accordance with the requirements of: •
ISO10218, Jan. 1992, Industrial Robot Safety
•
ANSI/RIA 15.06-1999
•
ISO/DIS 11161, Industrial automation systems - safety of integrated manufacturing systems - Basic requirements
•
DIN 19258 - Interbus-S, International Standard
Standards, safety fence The following standards are applicable to the safety fence surrounding the robot cell: •
ISO/DIS 11161, Industrial automation systems -safety of integrated manufacturing systems - Basic requirements
•
prEN 999:1995
Standards, robot cell The following standards are applicable when the robot is part of a robot cell:
8
•
IEN 294, Safety of machinery - Safety distance to prevent danger zones being reached by the upper limbs.
•
EN 349, Safety of machinery - Minimum gaps to avoid crushing of parts of the human body.
•
EN 811 Safety of machinery - Safety distance to prevent danger zones being reached by the lower limbs.
•
Pr EN 999 Safety of machinery - The positioning of protective equipment in respect of approach speeds of the human body.
•
EN 1088 Safety of machinery - Interlocking device associated with guards principles for design and selection.
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3HAC021313-001
1 Reference information, IRC5 1.3. Unit conversion
1.3. Unit conversion Converter table Use the table below to convert units used in this manual.
3HAC021313-001
Quantity
Units
Length
1m
3.28 ft
Weight
1 kg
2.21 lb
Pressure
1 bar
100 kPa
Force
1N
0.738 lbf
Moment
1 Nm
0.738 lbf-tn
Volume
1L
0.264 US gal
A
39.37 in 14.5 psi
9
1 Reference information, IRC5 1.4. Screw joints
1.4. Screw joints General This section details how to tighten the various types of screw joints on the controller. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials. Tightening torque Before tightening any screw, note the following: •
Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description. Any special torque specified overrides the standard value.
•
Use the correct tightening torque for each type of screw joint.
•
Only use correctly calibrated torque keys.
•
Always tighten the joint by hand, and never use pneumatical tools
•
Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow, flowing motion.
•
Maximum allowed total deviation from the specified value is 10%!
The table below specify the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws.
10
Dimension
Tightening torque (Nm) Class 4.8, oil-lubricated
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
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3HAC021313-001
1 Reference information, IRC5 1.5. Weight specifications
1.5. Weight specifications Definition In all repair and maintenance instructions, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way. To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. Example Below is an example of how a weight specification is presented: CAUTION! Caution! The transformer weighs 55 kg! All lifting equipment used must be sized accordingly!
3HAC021313-001
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1 Reference information, IRC5 1.6. Standard toolkit, IRC5
1.6. Standard toolkit, IRC5 General All service (repair, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools, i.e. all tools that are not considered standard as defined below, are listed in their instructions respectively. This way, the tools required are the sum of the Standard Toolkit and any tools listed in the instruction. Contents
12
Tool
Remark
Screw driver, Torx
Tx10
Screw driver, Torx
Tx25
Ball tipped screw driver, Torx
Tx25
Screw driver, flat blade
4 mm
Screw driver, flat blade
8 mm
Screw driver, flat blade
12 mm
Screw driver
Phillips-1
Box spanner
8 mm
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3HAC021313-001
1 Reference information, IRC5 1.7. Document references
1.7. Document references General The contents of this manual may include references to additional documentation necessary to perform certain procedures. This section specifies the article numbers for the referenced documentaion. Product specification, controller The product specification includes generic technical data. The specification listed below is the English version.
Document name
Document ID
Product Specification - IRC5 with FlexPendant
3HAC021785-001
Operators manual The operators manual contains instructions for daily operation of robot systems. The operator’s manual listed below is the English version.
Document name
Document ID
Operator’s manual - IRC5 with FlexPendant
3HAC 16590-1
Note
Application documentation Document name
Document ID
Trouble shooting manual - IRC5§
3HAC 020738-001
Getting started - IRC5 and RobotStudio Online 3HAC 021564-001 Operator’s manual - RobotStudio Online
3HAC 18236-1
Product manual, robot The product manuals include information about installation and service activities. The table below specifies the article numbers of the product mnauals for all robot models. The part number -001 is the English version.
3HAC021313-001
Document name
Document ID
Product manual, IRB 140
-
Product manual, IRB 1400
3HAC 021111-001
Product manual, IRB 2400
3HAC 022031-001
Product manual, IRB 4400
3HAC 022032-001
Product manual, IRB 6600/6650 type A
3HAC 020938-001
Product manual, IRB 6600/6650 type B
3HAC 023082-001
Product manual, IRB 6650S
3HAC 020993-001
A
13
1 Reference information, IRC5 1.7. Document references
14
Document name
Document ID
Product manual, IRB 7600
3HAC 022033-001
Product manual, IRB 940
3HAC 022054-001
A
3HAC021313-001
1 Reference information, IRC5 1.8. Lifting equipment and lifting instructions
1.8. Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment. This implies that the instructions delivered with the lifting equipment should be stored for later reference.
3HAC021313-001
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15
1 Reference information, IRC5 1.8. Lifting equipment and lifting instructions
16
A
3HAC021313-001
2 Spare Parts 2.1. Introduction
2 Spare Parts 2.1. Introduction Definitions This chapter specifies all spare parts and replacement articles of the IRC5 controller.
3HAC021313-001
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2 Spare Parts 2.2. Spare Parts IRC5, Control module
2.2. Spare Parts IRC5, Control module Control cabinet
xx0400001234
Spare parts
18
Pos
Spare part number
Description
A21
3HAC020665-001
Panel Board Unit
3HAC020901-001
Control panel 2-pos mode
3HAC020901-002
Control panel 3-pos mode
3HAC14605-1
Junction board DSQC616
3HAC020586-001
Harness,Panel board/ GTPU
3HAC021009-001
Harness-Panel board/Fan u
3HNE01586-1
Queue Tracker
3HAC14944-1
RS-232/422 converter
3HAC11819-1
Interbus slave with Cu
3HAC5579-1
InterBus-S adap.
3HAC5577-1
Profibus-DP adap
3HNE00009-1
Profibus DP Slave unit
3HNE00006-1
Interbus-S Unit
3HAB9715-1
Multipole con. X1-X4 10p
3HAB7342-1
Multipole con.set X7,X8
3HAB9743-1
Multipole con. X1-X4 16p
3HAC1836-1
Multipole con. X3 5p
3HAB9664-1 3
Multipole con. X6 6p
A
Note
DSQC 615
3HAC021313-001
2 Spare Parts 2.2. Spare Parts IRC5, Control module
Pos
Spare part number
Description
Note
3HAC0053-1
Multipole con. X8,X9 4p
3HAB9764-1
Multip. connector female
3HAC17970-1
Dig. 24 VDC I/O
DSQC 328A
3HAC12934-1
Customer I/O Power Supply
DSQC 608
3HAC17971-1
A D Combi I/O
DSQC 327A
3HAC17973-1
Dig. Relay I/O
DSQC 332A
3HAC020892-001
Heat exchanger unit
3HAC020890-029
Customer contact plate
3HAC12817-1
DeviceNet M/S
DSQC 603
3HAC15639-1
Ethernet board
DSQC 612
3HNE00554-1
Analog I/O Unit
APIP-02
3HNE00065-1
Circuit board
ENC-01
3HNE00025-1
Circuit board RIO
Mains connection and power supply
3HAC021313-001
3HAC020953-002
Transformer module
1,8kVA
G3
3HAC020150-001
Backup energy bank
DSQC624
G2
3HAC12928-1
Control Power Supply
DSQC 604
G4-G5
3HAC12934-1
Customer I/O Power supply
DSQC 608
A
19
2 Spare Parts 2.2. Spare Parts IRC5, Control module
Computer unit
xx0400001236
Spare parts
20
Pos
Spare part number
Description
Note
A3
3HAC020929-001
Computer A, SSD
Solid State drive
A3
3HAC020929-002
Computer B, HDD
Hard disk drive
3HAC12816-1
Robot com. card
DSQC 602
3HAC020464-001
Power supply
DSQC 625
3HAC020988-001
Mass memory
1xHDD
3HAC020988-002
Mass memory
2xHDD
3HAC020988-003
Mass memory
1xSSD
3HAC 12814-1
Main computer board
DSQC 600
3HAC020079-001
Main computer board
DSQC 623
3HAC020988-006
Fans
A
3HAC021313-001
2 Spare Parts 2.3. Spare Parts IRC5, Drive module
2.3. Spare Parts IRC5, Drive module Drive cabinet
xx0400001235
Spare parts
3HAC021313-001
Pos
Spare part number
Description
Info
A41.1
3HAC14546-1
Main servo drive unit
DSQC 617_3B3A
A41.1
3HAC14546-2
Main servo drive unit
DSQC 617_2E2C2B
A41.1
3HAC14546-3
Main servo drive unit
DSQC 617_3E1C
A41.1
3HAC14546-4
Main servo drive unit
DSQC 617_3G3T
A41.1
3HAC14546-6
Main servo drive unit
DSQC 617_3G3W
A41.1.3-5
3HAC14550-1
Single servo drive unit
DSQC 619_C
A41.1.3-5
3HAC14550-2
Single servo drive unit
DSQC 619_T
A41.1.3-5
3HAC14550-3
Single servo drive unit
DSQC 619_U
A41.1.3-5
3HAC14550-4
Single servo drive unit
DSQC 619_W
A41.2
3HAC14549-1
Rectifier
A41.2
3HAC14549-2
Rectifier
A
21
2 Spare Parts 2.3. Spare Parts IRC5, Drive module
Pos
Spare part number
Description
A41.2
3HAC14549-3
Rectifier
A41.3
3HAC14551-1
Capacitor unit
A41.3
3HAC14551-2
Capacitor unit
A41.3
3HAC14551-3
Capacitor unit
3HAC17281-1
DC-bus bar
DC_L6 long busbar with six connector groups
3HAC17281-3
DC-bus bar
DC_S2short busbar with two connector groups
G1
3HAC020465-001
Drive system power supply
DSQC 626
G1
3HAC020466-001
Drive system power supply
DSQC 627
A42
3HAC020919-001
Axis computer
DSQC 601
A43
3HAC13389-2
Contactor Interface board DSQC 611
3HAC020953-003
Transformer module
8,5kVA
3HAC020953-004
Transformer module
13kVA
3HAC020953-006
Transformer module
1,8kVA
3HAC6647-1
Duty time counter
24VDC
3HAC020900-001
Brake resistor bleeder
3HAC12924-3
Fan
3HAC020953-001
Fan holder with fans
3HAC7097-1
Mains line filter
Info
FlexPendant
22
3HAC12929-1
FlexPendant with cable
10m
3HAC11266-1
FlexPendant Cable
10m
3HAC12929-4
FlexPendant with cable
30m
3HAC11266-4
FlexPendant Cable
30m
A
3HAC021313-001
3 Circuit Diagram 3.1. Introduction
3 Circuit Diagram 3.1. Introduction Definitions This chapter specifies the circuit diagram of the IRC5 controller.
3HAC021313-001
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23
3 Circuit Diagram 3.1. Introduction
24
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3HAC021313-001
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
Prepared by, date:
Latest revision:
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Title page
ABB Automation Technologies AB Robotics SE-721 68 Västerås Sweden
© Copyright 2004 ABB All right reserved.
Additional copies of this document may be obtained from ABB at its then current charge.
We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
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3HAC020538-002 02
Document no.
Approved
Status:
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.
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.
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Project start Project manager Last revision Designed by Designed date Number of pages
Manufacture Type Type of installation Control cabinet Mains voltage Supply Control voltage Year of construction
3
: : : : : : :
: : : : : : :
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2004-05-05
: 2004-09-28
:
: : : 3HAC020538-002_Control
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Page description Title page Title page Table of contents: (1 - 30) Table of contents: (31 - 42) BLOCK DIAGRAM VIEW OF CONTROL MODULE MAINS CONNECTION POWER SUPPLY OPTION: POWER SUPPLY EMERGENCY STOP RUN CHAIN OPERATING MODE SELECTOR, 3 MOD EMERGENCY STOP RUN CHAIN RUN CHAIN OPERATING MODE SELECTOR, 2 MOD RUN CHAIN EXT OPERATING MODE SELECTOR, 2 RUN CHAIN EXT OPERATING MODE SELECTOR, 3 FPU, FLEXPENDANT OPTION: EXTERNAL CONNECTIONSYSTEM SIGNAL VIEW OF COMPUTER UNIT CABLING IN COMPUTER UNIT CABLING IN COMPUTER UNIT COMPUTER UNITCOOLING MAIN COMPUTER ROBOT COMMUNICATION CARD ROBOT COMMUNICATION CARD PROFIBUS DP M/S INTERBUS M/S DEVICENET ADAPTER DEVICENET ADAPTER DUAL RS232 CARD
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Status:
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Page description ETHERNET CARD DIGITAL PART OF COMBI I/O ANDDIGITAL I/O DIGITAL I/O UNIT COMBI I/O UNIT RELAY I/O UNIT RELAY I/O UNIT RELAY I/O UNIT ANALOGUE I/O UNIT REMOTE I/O UNIT INTERBUS SLAVE PROFIBUS DP SLAVE ENCODER UNIT
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= DOKUMENTE Plant: + INV Location: Sublocation: + Rev. Ind Page 4 Next 5 Total 42
2004-09-24
2004-09-24
2004-09-24
2004-09-24
2004-09-24
2004-09-24
2004-09-24 2004-09-24 2004-09-24
2004-09-24
2004-09-24
2004-09-24
Date
8
3HAC020538-002 02
Document no.
Approved
Status:
7
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
Prepared by, date:
Latest revision:
X22
F4
T3
Earth fault prot.
Service outlet
F5
Approved by, date:
S21
Control panel
G3
A21
G2
AC
XT16
Q2
X20
EPLAN
FPU
Panel board
Ultra cap
Drive
A3
DC
230V
5
Computer module
Lab/Office:
Field bus
4
Drive
3
I/Ox
unit
I/O
DC
7
DC
Customer connection
AC
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 5 Next 6 Total 42
G5
Option Customer PS
8
3HAC020538-002 02
Document no.
Approved
Status:
Customer connection
AC
G4
G6
AC
Option Customer PS
DC
6
Option Devicenet PS
BLOCK DIAGRAM
Ethernet service
Option Service outlet
2
USB
1
LAN
Q2
2004-09-24
Date
02
Modification
=CM+ORT/5
Name
X20
X22 (opt service outlet)
S21.1 (mode selector)
S21.2 (motor on pb)
S21.3 (emergency pb)
0
jsundin1
Edit.
Standard
Check.
2004-09-28
Date
G5
Origin
CM
XS8
XS58
G6 if not G5 if G5 G6 in I/O unit.
1
G4
2
Crea. for
XS13 XS5
G2
3
G3
Crea. by
EPLAN
XS17
4
XS3
A3
X11
X20
X18
A21 (Panel Board)
6
VIEW OF CONTROL MODULE
5
Approved
XT8
XT58
X28
XT6
I/O4
A22.X1
X12 X15
7
X9
X17 X14 X10
X2
X1
X6
X5
3HAC020538-002_Control
XT5
I/O2
X7 X18
X4
8
Page ORT
+ CM
I/O1
X3
I/O3
Page 6 42 Pg.
=CM+ORT/7
Epwr EN1 AS1 AS2 GS1 GS2 SS1 SS2 ES1 ES2
9
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
Prepared by, date:
Latest revision: 1
-X16
AWG16 BK AWG16 BK
2
-Q2 -171
BK
AWG16
BK
T1
L1
1
AWG16
-173
-172
BK
-X20
AWG16
-174
AWG16
L3
T3
GND
2
T2
GND
2
L2
230V AC2
BK
AWG16 BK
230V AC1
1
-182
/8.3 / -230V AC2
-X25
Approved by, date:
CONTROL MODULE
-181
/8.3 / -230V AC1
181
/9.5 / -230V AC1
DRIVE MODULE
-308
/9.2 / -230V AC1
181
/9.7 / -230V AC1
-309
/9.2 / -230V AC2
AWG16 BK
182
/9.5 / -230V AC2
3
182
/9.7 / -230V AC2
EPLAN
4
Lab/Office: AWG16 BK
-187
5
MAINS CONNECTION
AWG16 BK
-186
-F5
=CM +X22
-T3
EARTH FAULT BREAKER
CIRCUIT BREAKER
OPTION: SERVICE OUTLET
6
230V
115V
AWG16 BK
2
1 0V
AWG16 BK
4
3
4
2 8
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 7 Next 8 Total 42
3HAC020538-002 02
Document no.
Approved
4
2
-183
3
1 3
Status:
-F4
1
AWG16 BK
7
-184 -185
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
Prepared by, date:
Latest revision: 1
=CM +G2
-251
-250
/10.2 / -24V SYS
BU BU
2
BU 3
BU 4
Approved by, date:
-252
/10.2 / -0V SYS
24V SYS 24V COOL
PANEL BOARD
-253
/10.2 / -0V COOL
/10.2 / -24V COOL
1
-301
/20.2 / -24V PC
-X2
-302
/20.2 / -24V PC
PROCESS POWER SUPPLY
-303
/20.2 / -0V PC
-X1
-230V AC1 / /7.1 -230V AC2 / /7.3
5
AC -INPUT
AWG16 BK
-181
1 AWG16 BK
-182
-X3
3
1
BU 2
BU
24V PC
3
COMPUTER UNIT
3
BU
2
-304
/20.2 / -0V PC
BU 4
EPLAN
-X4
=CM -X1 +G3
4
+ 1
1
Lab/Office:
+ 2
2
NC 3
3
+ 5
6
6
POWER SUPPLY
4
5
ULTRA CAP
NC 4
7
7
8
8
+Sense
ULTRA CAP
5
9
NC
9
10
10 6
RD
8
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 8 Next 9 Total 42
3HAC020538-002 02
4
Approved
3
BK 7
Document no.
2
Status:
AWG24
/23.6 / -USB +5V
WH
GN
USB
MAIN COMPUTER
AWG28
/23.6 / -USB-BP2
1
AWG28
/23.6 / -USB-BP2
-X5
AWG24
/23.6 / -USB_GND
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
Prepared by, date:
Latest revision:
-X2
DEVICENET POWER SUPPLY =CM -X1 +G6
AWG16
BK
-230V AC1 / /7.2
+
L
AC
-308
1
/29.1 / -+24V devicenet
BK
-230V AC2 / /7.3
+
2
Approved by, date:
AWG16
N
DC
-309
/29.1 / -0V devicenet GND
/32.1 / -+24V devicenet /32.1 / -0V devicenet
/35.1 / -+24V devicenet /35.1 / -0V devicenet 3
/38.1 / -+24V devicenet /38.1 / -0V devicenet
/39.1 / -+24V devicenet /39.1 / -0V devicenet
/40.2 / -+24V devicenet /40.2 / -0V devicenet
EPLAN
4
/41.1 / -+24V devicenet /41.1 / -0V devicenet
1
AC
181
-230V AC1 / /7.2
1
OPTION: POWER SUPPLY
-X2
5
CUSTOMER POWER SUPPLY =CM -X1 +G4
Lab/Office:
/42.1 / -+24V devicenet /42.1 / -0V devicenet
24V I/O
182
-230V AC2 / /7.3
3
5
DC
0V I/O
Customer Connection
3
24V I/O 2
0V I/O 4
6
-230V AC2 / /7.3
3
5
2 4
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 9 Next 10 Total 42
3
Customer Connection
182
8
3HAC020538-002 02
1
DC
Document no.
-230V AC1 / /7.2
1
AC
181
7
Approved
Status:
-X2
CUSTOMER POWER SUPPLY =CM -X1 +G5
24V I/O 0V I/O
24V I/O 0V I/O
Prepared by, date:
Latest revision:
PROCESS POWER SUPPLY
1
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
BU BU
-252
-253
/8.2 / -24V COOL
/8.2 / -0V COOL
Approved by, date:
EMERGENCY STOP RELAY SIGNALS
EXTERNAL SUPPLY
ES2:int
ES1:int
ES2 bottom ES1 bottom 0V 24V Panel
Sep ES2:B
Sep ES1:B
6
8
7
10
9
2
ES2 OUT:B ES1OUT:B
EMERGENCY STOP OUTPUT 2
Sep ES2:A Sep ES1:A
1
ES1OUT:A ES2 OUT:A
EMERGENCY STOP OUTPUT 1
4
3
6
8
7
10
0V
A2 A1
24V PANEL
U
24V PANEL
-ES1
9
2
1
5
4
3
-X1 -X2
4
3
2
1
-X12
PANEL BOARD
5
0V 24V Panel
=CM +A21
3
Run CH1 top Run CH2 top
EXTERNAL EMERGENCY STOP PB
BU
-251
/8.2 / -0V SYS
ES1 top ES2 top
BU
-250
/8.2 / -24V SYS
2
0V
U
ES1
EPLAN
-ES2
RunCh+
RunCh_0V
4
A1
Lab/Office:
ES2
A2
+ORT/12.6 / -RunCh+ +ORT/12.5 / -RunCh_0V +ORT/12.6 / -RCH2 +ORT/12.7 / -RCH1
EMERGENCY STOP
SOFT_ESI
SOFT_ESO
5
RunCh_0V RunCh+
6
8
15
11
13
8
6
4
2
7
5
3
1
-X11
16
12
14
17
-X9 18
6
7
5
-X10
-237 -238 -233 -234 -231 -232 -235 -236
-209 -211 -212 -210
WHBN
WHBU
BU
OG
11
21
12
22
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 10 Next 11 Total 42
-0V_Sig.ref. / /24.5
JUNCTION BOARD
ROBOT COMM. CARD
EMERGENCY PB
-24V_Sig.ref. / /24.5 -RS485+ / /24.5 -RS485- / /24.5
-S21.3
-ES FPU 1:A / /17.2 -ES FPU 2:A / /17.2 -ES FPU 2:B / /17.2 -ES FPU 1:B / /17.2
8
3HAC020538-002 02
Document no.
Approved
Status:
AWG24
ES panel 1:B
ES panel 1:B
ES panel 2:B
ES panel 2:B
ES panel 2:A
ES panel 2:A
ES panel 1:A
ES panel 1:A
AWG20
AWG20
AWG20
AWG20
7
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
-ENABLE1
-AS1
-AS2
-GS1
-GS2
-SUP_ST1
-SUP_ST2
-ES1
-ES2
Prepared by, date:
Latest revision:
=CM +A23
OPTION: STATUS LED ON FRONT
8
6
5
2
7
3
4
1
-X2
8
6
4
2
7
3
4
1
2
OP_AUTO OP_MAN_FS 4
3
-X15
8
6
5
2
-X20
9
7
5
3
1
8
6
4
10
-X4
9
7
5
3
2
0V
RS485+ RS48524V DC
0V
General out8
General out7
General out6
General out5
General out4
General out3
General out2
General out1
+24V
0V
General in8
General in7
General in6
General in5
General in4
General in3
General in2
General in1
EPLAN
+ORT/13.3 / -SPEED +ORT/12.5 / -EN1 +ORT/12.5 / -EN2 +ORT/12.5 / -MAN1 +ORT/12.4 / -MAN2 24V PANEL
Lab/Office:
>1
1
3
2
-363
=CM +E3
AWG20 BU;BU
-
2
M
1~
-361
-360
-362
1
+
AWG20
AWG20 BU
AWG20
MONLMP
24V PANEL
MOTON
-S21.2
0V
24V panel
BK
BN
RD
X1
13
=CM +E2
1
2 4 8
-S21.1.X1
3
2
1
4
7
OPTION
JUNCTION BOARD
6
8
5
13
141620
M -
8
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 11 Next 12 Total 42
3
2
1
-X1
EXT COMPUTER FAN
17
182224
3HAC020538-002 02
Document no.
Approved
Status:
1
3
2
-X18
X2
14
MOTOR ON PB
5
MODE SELECTOR -S21.1 6 1210
AUTO2
MAN2
MAN FS2
AUTO1
MAN1
MAN FS1
OPTION: DOOR FAN 52
-230
-229 -228
-220 -224
-227 -226 -225 -223 -222 -221
-X1
-24V FPU_POWER / /17.2 -0V / /17.2 -EN1_1 / /17.2 -EN1_2 / /17.2 -FPU START / /17.2
EXTERNAL ENABLE DEVICE
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20 BU;BU
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20
AWG20
EN2_1A EN2_1B EN2_2A EN2_2B
-X18 -364
19
10
1
3
6
8
-X9
9
7
-205 -206 -207 -208 -213
RUN CHAIN OPERATING MODE SELECTOR, 3 MODES
FAN 0V
TACHO
24V COOL
9
5
2
4
7
9
3
-X6
10
8
4
2
1
-X10
EXT.MAN2
7
EXT.AUTO2
6
EXT MAN FS2
1
5
EXT.MAN1
-X3
4
EXT.AUTO1
3
EXT.COMMON2
PANEL BOARD
1
BN
WHBN
GN
WHGN
WHBU
BU
OG
WHOG
=CM +A21
OP_COM OP_MAN
AWG26
Approved by, date:
2
EXT.COMMON1
1
-245 -244 -243 -246 -241 -240 -239 -242 EXT MAN FS1
+
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
Prepared by, date:
Latest revision: 1
SUPERIOR STOP
GENERAL STOP
AUTO STOP
3
2
4
6
5
1
4
5
1
10
-X6
2
8
3
9
11
6
Approved by, date:
SS2-
SS1SS2+
SS1+
GS2-
GS1GS2+
AS2GS1+
AS1AS2+
AS1+ 7
12
-X5
SS2
SS1
24V PANEL 0V
24V PANEL 24V PANEL 0V 0V
PANEL BOARD =CM +A21
2
GS2
GS1
AS2
AS1 3
SS2
SS1
SOFT SS
GS2
GS1
AS2
AS1
SOFT AS
EPLAN
SOFT GS
4
-MAN2 / +ORT/11.4 Lab/Office:
-MAN1 / +ORT/11.4
EMERGENCY STOP
5
-EN2 / +ORT/11.4 -EN1 / +ORT/11.4 -RunCh_0V / +ORT/10.5
&
+ORT/13.3 / -ENABLE2_1 +ORT/13.3 / -ENABLE2_2 +ORT/13.3 / -ENABLE2_3 +ORT/13.3 / -ENABLE2_4
-RunCh+ / +ORT/10.5
&
6
CH2
+ORT/13.4 / -RCH2
-RCH2 / +ORT/10.6
8
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 12 Next 13 Total 42
3HAC020538-002 02
Document no.
-RCH1 / +ORT/10.6 7
Approved
Status:
CH1
+ORT/13.4 / -RCH1
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
Prepared by, date:
Latest revision:
1
PANEL BOARD
Approved by, date:
=CM +A21
2
EPLAN
Lab/Office:
RUN CHAIN
24V PANEL
0V
24V PANEL
0V
24V PANEL
0V
9
7
5
4
1
9
7
5
4
10
8
6
3
2
9
7
5
4
1
-X17
10
8
6
3
2
1
-X14
10
8
6
3
2
9
7
5
4
1
-X8
10
+ORT/12.5 / -ENABLE2_3 +ORT/12.5 / -ENABLE2_4
8
+ORT/12.5 / -ENABLE2_2
2
-X7
6
24V PANEL
0V
+ORT/12.5 / -ENABLE2_1
5
3
+ORT/12.6 / -RCH2
+ORT/12.7 / -RCH1
4
+ORT/11.4 / -SPEED
3
RUN CH1 RUN CH1Ret
RUN CH2Ret RUN CH2 SPEED 0V ENABLE2_4 ENABLE2_4Ret AC_ON1 0V
RUN CH1 RUN CH1Ret
RUN CH2Ret RUN CH2 SPEED 0V ENABLE2_3 ENABLE2_3Ret AC_ON1 0V
RUN CH1 RUN CH1Ret
RUN CH2Ret RUN CH2 SPEED 0V ENABLE2_2 ENABLE2_2Ret AC_ON1 0V
RUN CH1 RUN CH1Ret
RUN CH2Ret RUN CH2 SPEED 0V ENABLE2_1 ENABLE2_1Ret AC_ON1 0V
6
Drive module4 A43.X1
Drive module3 A43.X1
Drive module2 A43.X1
Drive module1 A43.X1
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 13 Next 14 Total 42
8
3HAC020538-002 02
Document no.
Approved
Status:
if not used
if not used
if not used
if not used
if not used
if not used
CONTROL MODULE
7
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
PANEL BOARD =CM +A21
Prepared by, date:
Latest revision:
1
Approved by, date:
2
3
9
19
10
1
5
6
7
2
3
-X9
-228
-230
-229
AWG20 BU
AWG20 BU
AWG20 BU
EPLAN
-220
-224
-225
-226
-221
-222
4
Lab/Office:
24V PANEL
MONLMP
MOTON
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
X2
14
2
3
X1
13
MOTOR ON PB
1 .5
5 6
7 .5
9 10 .5
11
6
RUN CHAIN OPERATING MODE SELECTOR, 2 MODES
-S21.2
24V panel
0V
-S21.1
MODE SELECTOR
AUTO1
MAN1
AUTO2
MAN2
5
14
13 15
-242
-246
-244
-245
-240
-241
EXT.MAN2
EXT.AUTO2
EXT.MAN1
EXT.AUTO1
EXT.COMMON1
EXT.COMMON2
OPTION
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 14 Next 15 Total 42
8
4
5
1
2
3
6
7
-S21.1.X1
8
3HAC020538-002 02
Document no.
Approved
Status:
OG
OG
OG
OG
OG
OG
7
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
Prepared by, date:
Latest revision:
=CM +A32
15
11
13
17
19
10
5
7
8
6
4
2
9
7
5
3
1
-X10
16
12
14
18
9
1
6
2
3
-X9
2
1
Approved by, date:
2
6
3
-A8
ROBOT COMMUNICATION CARD
PANEL BOARD =CM +A21
1
BN/GN
BN/BK BN/RD BN/OG BN/YE
CONTROL MODULE
3
TPU_START
24V TPU 0V EN1_1 EN1_2
EPLAN
4
Lab/Office:
MAN2 AUTO2 MAN1 AUTO1
AWG20 AWG20 AWG20 AWG20
-230 -228
-229 MONLMP
MOTON
2
3
AWG24
GN
WHGN
OG
.6
5 6
7 .6
9 10 .6
11
X1
13
ES panel 1:B
ES panel 1:B
ES panel 2:B
ES panel 2:B
ES panel 2:A
ES panel 2:A
ES panel 1:A
ES panel 1:A
X2
14
MOTOR ON PB
WHOG
24V PANEL
-237 -238 -233 -234 -231 -232 -235 -236
AWG20
AWG20
AWG20
AWG20
1
-S21.2
0V 24V panel
AWG20
-S21.1
MODE SELECTOR
-224 -220
TD+ TDRD+ RD-
15
11
13
17
19
10
5
7
-222 -221 -226 -225
6
RUN CHAIN EXT OPERATING MODE SELECTOR, 2 MODES
16
12
14
18
9
1
6
2
3
-Ext.A21.X9
EXT. CONTROL PANEL
5
-246 -242
EXT.COMMON1
EXT.COMMON2
EXT.MAN2
EXT.AUTO2
EXT.MAN1
EXT.AUTO1
12
22
4
2
8
6
4
2
3
1
-X2
9
7
5
3
1
-X3
8
2
6
3HAC020538-002 02
Document no.
4
3
7
-S21.1.X1
8
OPTION
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 15 Next 16 Total 42
JUNCTION BOARD
11
21
EMERGENCY PB
Approved
Status:
=CM +A22
-S21.3
14
13 15
-241 -240 -245 -244
7
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
Prepared by, date:
Latest revision:
=CM +A32
8
6
4
2
EPLAN
Lab/Office:
5
3
6
15
11
13
17
9
7
5
3
1
1
Approved by, date:
2
6
3
-A8
BN/GN
TPU_START
15
11
13
17
AWG20
AWG20
MAN2
0V
ES panel 1:B
ES panel 1:B
ES panel 2:B
ES panel 2:B
ES panel 2:A
ES panel 2:A
ES panel 1:A
GN
WHGN
OG
MONLMP
MOTON
ES panel 1:A
WHOG
AWG20
AWG20
AWG20
AWG24
-237 -238 -233 -234 -231 -232 -235 -236
-230 -228
-229
1
.7
17
182224 .7
X2
14
X1
13
MOTOR ON PB
2 4 8
-S21.2
.7
24V PANEL
5
6 1210
AWG20 24V panel
AWG20
-S21.1
-224 -220
MAN1
MAN FS1
AUTO2
MODE SELECTOR
-223 -222 -221
AWG20
AWG20
AUTO1 AWG20 AWG20 MAN FS2
-227 -226 -225
6
RUN CHAIN EXT OPERATING MODE SELECTOR, 3 MODES
TD+ TDRD+ RD-
16
12
14
18
19 9
1
2
4
7
8
-Ext.A21..X9
EXT. CONTROL PANEL
5
19
24V TPU 0V EN1_1 EN1_2
4
10
BN/BK BN/RD BN/OG BN/YE
CONTROL MODULE
3
10
5
3
6
-X10
16
12
14
18
9
1
2
4
7
8
-X9
2
ROBOT COMMUNICATION CARD
PANEL BOARD =CM +A21
1
11
21
12
22
6
2
8
6
4
2
4
5
7
2
OPTION
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 16 Next 17 Total 42
8
6
1
3
-S21.1.X1
8
3HAC020538-002 02
Document no.
3
1
-X2
9
7
5
3
1
-X3
JUNCTION BOARD
Approved
Status:
=CM +A22
EXT.COMMON2
EXT.COMMON1
EXT MAN FS1
EXT.MAN1
EXT.AUTO1
EXT MAN FS2
EXT.MAN2
EXT.AUTO2
EMERGENCY PB
-242 -246
-S21.3
13
141620
-245 -244 -243 -241 -240 -239
7
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AWG20 BU AWG20 BU
AWG20 AWG20
AWG20 BU
-205 -206
-207 -208
-213
/11.6 / -24V FPU_POWER
/11.6 / -0V
/11.6 / -EN1_1
/11.6 / -EN1_2
/11.6 / -FPU START
Prepared by, date:
Latest revision:
WHGN GN
/24.6 / -RD+
/24.6 / -RD-
Approved by, date:
OG
/24.6 / -TD-
WHOG
AWG20 BU
-210
/10.7 / -ES FPU 1:B
/24.6 / -TD+
AWG20
-212
/10.7 / -ES FPU 2:B
AWG24
AWG20 BU
-211
/10.7 / -ES FPU 2:A
3
AWG20 BU
/10.7 / -ES FPU 1:A
2
-209
ROBOT COMM. CARD
PANEL BOARD
PANEL BOARD
1
=CM +A22
6
3
2
1
-X2
9
4
3
2
1
6
8
Lab/Office:
4
6
5
3
X22.XP1
OPTION: FPU-PLUG
FPU, FLEXPENDANT
16
15
14
13
11
17
7
8
2
12
1
4
6
5
3
5 7
-X1
5
-X3
EPLAN
JUNCTION BOARD
4
6
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 17 Next 18 Total 42
ETH_FPU
8
3HAC020538-002 02
Document no.
Approved
-K2
EN-DEVICE
-K1
EMERGENCY-STOP
FLEXPENDANT
Status:
=CM +FPU
7
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
ES2 OUT B
ES2 OUT A
ES1 OUT B
ES1 OUT A
Sep ES1:B
Sep ES2:B
Sep ES2:A
Sep ES1:A
ES1 top
ES2 top
0V
Run CH2 top
Run CH1 top
24V PANEL
0V
24V PANEL
ES2 bottom
ES1 bottom
Prepared by, date:
Latest revision:
=CM +A21
PANEL BOARD
1
2
1
10
9
3
4
5
8
7
-X2
Approved by, date:
2
1
10
9
3
5
4
8
7
-X1
2
-287
-286
-285
-284
-271
-270
-269
-268
-267
-266
-265
-264
-263
-262
-261
-260
3
OG
OG
OG
OG
OG
OG
OG
OG
OG
OG
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
OG
OG
B8
B7
A8
A7
A6
B6
B5
A5
A4
B4
B3
A3
A2
B2
B1
A1
-XS/XP3
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
EPLAN
4
Lab/Office:
=CM +A21
10
9
8
7
6
5
4
3
2
1
-X6
2
4
1
3
5
6
8
10
7
9
11
12
-X5
6
OPTION: EXTERNAL CONNECTION SYSTEM SIGNALS
24V PANEL
SS2+
SS1+
SS2-
SS1-
0V
GS2-
GS2+
0V
AS2-
AS2+
24V PANEL
GS1-
GS1+
0V
AS1-
AS1+
24V PANEL
PANEL BOARD
5
-288
-292
-290
-293
-291
-289
-283
-282
-281
-280
-279
-278
-277
-276
-275
-274
-273
-272
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 18 Next 19 Total 42
A9
C9
B9
C10
B10
A10
D8
D7
D6
D5
D4
D3
D2
D1
C8
C7
C6
C5
C4
C3
C2
C1
-XS/XP3
8
3HAC020538-002 02
Document no.
Approved
Status:
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
AWG20 BU
7
2004-09-24
Date
02
Modification
=CM+ORT/18
0
Name
jsundin1
Edit.
Standard
Check.
2004-09-24
Date
1
CM Origin
2
Crea. for
USB1,2
X1
3
Crea. by
EPLAN
PWR (green)
USB3,4
Slot 1
HDD (yellow)
LAN
Slot 2
Slot 4
Slot 5
6
7
Approved
8
3HAC020538-002_Control
A33 Profibus DP M/S A37 Interbus M/S (optical fiber) A38 Interbus M/S (copper wire) A35 Devicenet
VIEW OF COMPUTER UNIT
Slot 3
A32 (RCC)
5
SERIAL PORT A
A3 Computer unit
4
Page ORT
+ CM
Page 19 42 Pg.
=CM+ORT/20
9
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Prepared by, date:
Latest revision:
PROCESS POWER SUPPLY
1
BU BU BU BU
-302 -303 -304
/8.3 / -24V PC
/8.3 / -0V PC
/8.3 / -0V PC
Approved by, date:
/8.3 / -24V PC
-301
2
=CM +A3
3
3
2
EPLAN
Lab/Office:
MOTHER BOARD POWER
1
-P1
2 3
-PSU-X2
-P1
-PSU-X2
1
-PSU-X1
-P1
P1
-IDEpwr
GND
BK
GND GND +5V +5V
BK BK RD RD
=CM +A31
19
17
15
13
11
9
7
5
3
1
20
18
16
14
12
10
8
6
4
2
-J4H1
MAIN COMPUTER
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 20 Next 21 Total 42
8
3HAC020538-002 02
Document no.
Approved
Status:
-IDEpwr_GND / +ORT/21.2 -IDEpwr_+5V / +ORT/21.2
GND BK
PS_ON GN
-12V
BU
GND
+3.3V
OR
BK
+12V
+5VSB
YE
VT
PWR_OK
+5V
RD
GY
+5V GND
BK
GND
+3.3V
+3.3V
7
RD
BK
OR
OR
6
CABLING IN COMPUTER UNIT
V+
V-
-X1
4
5
COMPUTER POWER SUPPLY
1
=CM +G31
-X1
COMPUTER UNIT
4
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
=CM +A3
Prepared by, date:
Latest revision:
1
Approved by, date:
+ORT/20.7 / -IDEpwr_GND +ORT/20.7 / -IDEpwr_+5V
COMPUTER UNIT
2
3
=CM +D31
-X2
4
3
2
1
-X1 1
-X2
OPTION: HARD DISK DRIVE
4
3
2
1
-X1
SOLID STATE DRIVE
EPLAN
Lab/Office:
5
40
40
=CM +A31
ATA/IDE
-J6H1
ATA/IDE
-J6H1
MAIN COMPUTER
6
CABLING IN COMPUTER UNIT
REMARK: P1 & J6H1 CONNECTS TO EITHER D32 OR D31 DEPENDING OF CHOSED OPTION.
GND +5V
GND +5V
=CM +D32
4
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 21 Next 22 Total 42
8
3HAC020538-002 02
Document no.
Approved
Status:
7
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
=CM +A31
=CM +G31
3
1
2 3
1
-J9H2
2
-J9H1
Approved by, date:
MAIN COMPUTER
P1
COMPUTER POWER SUPPLY
COMPUTER UNIT
2
GND +12V
BK YE
3
EPLAN
4
Lab/Office:
FAN1_TACH
YE
WH
COMPUTER UNIT COOLING
GND +12V
BK
FAN2_TACH
YE
WH
GND +12V
BK
5
2
1
2
1
-C1
-C2
6
BK
RD
BK
RD
-E23
-E22
M
-
CHASSIS BLOWER
M
-
CHASSIS BLOWER
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 22 Next 23 Total 42
8
3HAC020538-002 02
Document no.
Approved
Status:
AWG 24
AWG 24
7
+
Prepared by, date:
Latest revision:
=CM +A3
1
+
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
0V
TX-
TX+
RX-
Prepared by, date:
RX+
2
8
6
4
2
8
6
4
2
Approved by, date:
9
7
5
3
1
9
7
5
3
1
OPTION: 232/485 SERIE CONVERTER =CM +A39 -X1 -X2
COMPUTER UNIT
OPT. EXTERNAL PWR
Latest revision:
=CM +A3
1
RTS
0V
DTR
RECEIVE IN
TRANSMIT OUT
3
=CM +A31
9
7
5
3
1
-A1
EPLAN
8
6
4
2
SERIAL PORT A
MAIN COMPUTER
4
Lab/Office:
3
1
1
2
3
1
3
1
MAIN COMPUTER
4
2
-USB4
4
2
-USB3
4
3
-USB2
4
3
2
-USB1
6
2
1
-LAN1
3
1
4
2
-J9H3
5
K
RX-
RX+
TX-
TX+
A
AWG24
AWG24
AWG28
AWG28
AWG24
AWG24
AWG28
AWG28
K
BK
RD
GN
WH
BK
RD
GN
WH
HDD LED (YELLOW)
A
PWR LED (GREEN)
6
=CM +X24
4
1
3
2
CONTROL MODULE
3HAC020538-002 02
Document no.
8
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 23 Next 24 Total 42
PROCESS POWER SUPPLY
Approved
Status:
-USB-BP2 / /8.7 -USB-BP2 / /8.7 -USB +5V / /8.6 -USB_GND / /8.7
GND
+5V
USB-BP1
USB-BP1
7
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
Prepared by, date:
Latest revision:
1
3
-X1
PCI BUS
ROBOT COMMUNICATION CARD
Approved by, date:
=CM +A32
2
EPLAN
ETH_FPU
RS 485
4
-A8
7
5
3
1
8
2
5
6
Lab/Office:
7
1
4
3
Green
8
6
4
2
Blue
-X8
GN
WHGN
OG
WHOG
WHBN
WHBU
BU
OG
-RD+ / /17.2 -RD- / /17.2
-TD+ / /17.2 -TD- / /17.2
-0V_Sig.ref. / /10.7
-24V_Sig.ref. / /10.7 -RS485+ / /10.7 -RS485- / /10.7
6
ROBOT COMMUNICATION CARD
AWG24
AWG24
5
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 24 Next 25 Total 42
8
3HAC020538-002 02
Document no.
Approved
Status:
FLEXPENDANT
PANEL BOARD
7
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
Prepared by, date:
Latest revision:
1
=CM +A32
Approved by, date:
2
ROBOT COMMUNICATION CARD
3
EPLAN
ETH_SERVICE
ETH_DRIVE
4
-A7
7
4
3
7
5
3
Lab/Office:
8
6
4
2
1
Yellow
8
5
6
2
1
Red
-A9
RX-
TX+ TXRX+
TX+ TXRX+ RX-
AWG26
AWG26 AWG26 AWG26
WHOG
BU WHBU OG
6
ROBOT COMMUNICATION CARD
5
6
3
2
1
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 25 Next 26 Total 42
SERVICE PORT
DRIVE MODULE AXIS COMPUTER
8
3HAC020538-002 02
Document no.
Approved
Status:
=CM +X23
CONTROL MODULE
7
Prepared by, date:
Latest revision:
1
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
PCI BUS
-X1
PROFIBUS DP M/S
Approved by, date:
=CM +A33
2
3
MASTER
SLAVE
8
5
3
8
5
3
6
4
1
-X3
6
4
1
-X2
EPLAN
SHIELD RXD/TXD-P CONTROL-P GND +5VDC RXD/TXD-N
SHIELD RXD/TXD-P CONTROL-P GND +5VDC RXD/TXD-N
4
Lab/Office:
Customer Connection
PROFIBUS DP M/S
5
OPTION & HARNESS TO CUSTOMER I/O
6
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 26 Next 27 Total 42
8
3HAC020538-002 02
Document no.
Approved
Status:
7
Prepared by, date:
Latest revision:
1
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
=CM +A37
A37.2
REMOTE
REMOTE OUT
REMOTE IN
5
2
6
4
1
-X1
GY (OUT)
BK (IN)
-FO3
GY (OUT)
BK (IN)
-FO2
GY (OUT)
BK (IN)
-FO1
0V
24V+
-X2
3
TXD RXD GND RTS CTS
LW/OG
LW/BK
LW/OG
LW/BK
LW/OG
LW/BK
0V
24V
1)
4
OPTION & HARNESS TO CUSTOMER I/O EPLAN
1) IT IS IMPORTANT THAT 24 DC EXT SUPPLY ALWAYS IS AVAILABLE OTHERWISE THE INTERBUS CAN NOT WORK IF THE CONTROLLER IS TURNED OFF.
Approved by, date:
PCI BUS
-Z1
A37.1
INTERBUS M/S (OPTICAL FIBRE)
2
Lab/Office:
=CM +A38
INTERBUS M/S
5
A38.2
PCI BUS
-Z1
A38.1
5
2
8
4
7
6
5
7
6
5
4
7
1)
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 27 Next 28 Total 42
TXD RXD GND RTS CTS
DO DON DI DIN GNDIM GRND VCCIM VCC
DO DON DI DIN GRND VCCISO RBST
DO DON DI DIN GNDISI
0V
24V
8
3HAC020538-002 02
Document no.
Approved
6
4
1
-X3
5
3
2
1
-X2
9
3
2
1
-X1
3
2
1
-X5
0V
24V+
-X4
Status:
RS232
REMOTE
REMOTE OUT
REMOTE IN
INTERBUS M/S (COPPER WIRE)
6
OPTION & HARNESS TO CUSTOMER I/O
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
Prepared by, date:
Latest revision:
1
=CM +A35
P1
Approved by, date:
PCI BUS
DEVICE NET ADAPTER
2
2 3 4
2 3 4
Lab/Office:
5
1
1
5
-A35.X1
EPLAN
4
-J1
3
-V+ / /29.2
-CAN_H / /29.2
-DRAIN / /29.2
-CAN_L / /29.2
-V- / /29.2
RD
WH
SC
BU
BK
DEVICENET ADAPTER
5
6
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 28 Next 29 Total 42
OPTION
8
3HAC020538-002 02
Document no.
Approved
Status:
2
4
1
5
3
-XS17
CONTROL MODULE
7
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
/28.5 / -V/28.5 / -CAN_L /28.5 / -CAN_H /28.5 / -V+ /28.5 / -DRAIN
Prepared by, date:
Latest revision:
/9.2 / -+24V devicenet
/9.2 / -0V devicenet
1
Approved by, date:
2
3
5
4
3
2
1
-A35.X2
5
4
3
2
1
-I/O4
5
4
3
2
1
-I/O3
5
4
3
2
1
-I/O2
5
4
3
2
1
-I/O1
EPLAN
120 OHM
4
Lab/Office:
DEVICENET ADAPTER
-V- / /42.1 -CAN_L / /42.1 -CAN_H / /42.1 -V+ / /42.1 -DRAIN / /42.1
Encoder unit
Profibus DP slave
-V- / /41.1 -CAN_L / /41.1 -CAN_H / /41.1 -V+ / /41.1 -DRAIN / /41.1 BK BU WH RD SC BK BU WH RD SC
Interbus slave
Remote I/O unit
Analogue I/O unit
Relay I/O unit
Digital I/O unit
-V- / /40.2 -CAN_L / /40.2 -CAN_H / /40.2 -V+ / /40.2 -DRAIN / /40.2
-V- / /39.1 -CAN_L / /39.1 -CAN_H / /39.1 -V+ / /39.1 -DRAIN / /39.1
-V- / /38.1 -CAN_L / /38.1 -CAN_H / /38.1 -V+ / /38.1 -DRAIN / /38.1
-V- / /35.1 -CAN_L / /35.1 -CAN_H / /35.1 -V+ / /35.1 -DRAIN / /35.1
-V- / /32.1 -CAN_L / /32.1 -CAN_H / /32.1 -V+ / /32.1 -DRAIN / /32.1
6
BK BU WH RD SC
BK BU WH RD SC
BK BU WH RD SC
BK BU WH RD SC
BK BU WH RD SC
5
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 29 Next 30 Total 42
8
3HAC020538-002 02
Document no.
Approved
Status:
OPTION: HARNESS TO CUSTOMER I/O
7
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
Prepared by, date:
Latest revision:
1
Approved by, date:
2
=CM +A34
X5
PCI BUS
DUAL RS232 CARD
3
EPLAN
4
Lab/Office:
COM1 RS232
MC CONSOLE RS232
9
7
5
3
1
-X2
9
7
5
3
1
DUAL RS232 CARD
8
6
4
2
8
6
4
2
-X1
5
COM1_RXD COM1_TXD COM1_DTR 0V COM1_DSR COM1_RTS-N COM1_CTS-N
CONSOLE_RXD CONSOLE_TXD CONSOLE_DTR 0V CONSOLE_DSR CONSOLE_RTS-N CONSOLE_CTS-N
6
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 30 Next 31 Total 42
8
3HAC020538-002 02
Document no.
Approved
Status:
7
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
Prepared by, date:
Latest revision:
1
=CM +A36
Approved by, date:
2
X1
PCI BUS
ETHERNET CARD
3
EPLAN
4
8
6
4
2
-A3
8
6
4
2
-A2
8
6
4
2
-A1
7
5
3
1
7
5
3
1
7
5
3
1
Lab/Office:
RX-
TX+ TXRX+
RX-
TX+ TXRX+
RX-
TX+ TXRX+
ETHERNET CARD
5
7
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 31 Next 32 Total 42
8
3HAC020538-002 02
Document no.
Approved
Status:
DRIVE MODULE 4 (OPTION)
DRIVE MODULE 3 (OPTION)
DRIVE MODULE 2 (OPTION)
6
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
Prepared by, date:
Latest revision:
OR PREVIOUS I/O UNIT
3)
2
2) 120 ohm 2 1
3) CONNECTED IN THE LAST CONNECTOR IN THE CAN-BUS CIRCUIT.
Approved by, date:
3
TO NEXT I/O UNIT
2) RESISTANS 120 OHM SHALL ALWAYS BE CONNECTED IN THE FIRST AND THE LAST CONNECTOR IN THE CAN-BUS CIRCUIT.
1) JUMPERS PLACED ACCORDING TO THE ACTUAL NODE ADDRESS.
/29.5 / -DRAIN
/29.5 / -V/29.5 / -CAN_L /29.5 / -CAN_H /29.5 / -V+
/9.3 / -+24V devicenet /9.3 / -0V devicenet
1
1)
0V NA0 NA1 NA2 NA3 NA4 NA5
I/Ox
5
11
9
7
3
4
1
12
10
8
6
5
2
-X5
EPLAN
2
1
2
47nF
1
47nF
Lab/Office:
0V
K
A
A
10
8
6
4
2
9
7
5
3
9
7
5
3
1
-X4
10
8
6
4
2
1
-X3
XTXX.X4
XTXX.X3
6
INPUT CH.9 10 11 12 13 14 15 16 0V
INPUT CH.1 2 3 4 5 6 7 8 0V
DIGITAL PART OF COMBI I/O AND DIGITAL I/O UNIT
K
A
K
A
K
DIGITAL PART OF COMBI I/O AND DIGITAL I/O UNIT
4
= CM Plant: + ORT Location: Sublocation: + Rev. Ind Page 32 Next 33 Total 42
8
3HAC020538-002 02
Document no.
Approved
Status:
7
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
Prepared by, date:
Latest revision:
1
I/Ox
0V
DIGITAL I/O UNIT
Approved by, date:
2
1
2
1
47nF
2
47nF
K
A
K
A
3
OUTPUT CH 9-16
OUTPUT CH 1-8
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