R08.1 v1.

2
IRC5 Hardware
Yngve Carlsson Training related
to spec. form
ABB Robotics - 1, rev0
 Content – headlines referring to spec form

Chapter starting on slide

1 Manipulator N/A
2 Basic 6
3 Floor cables 32
4 Control module 37
5 Drive module 74
7 Process 89
Stand-alone controller 92
Specific specification form
ABB Robotics - 2, rev0
ABB Robotics - 3, rev0 R07.2 => First delivery date 2007-11-05
 R08.1 => First delivery date 2008-05-21
Specification forms published in ABB Library
Change date in BOL
ABB Robotics - 4, rev0
 Inside & Interfaces
Powerful main CPU

Industrial CompactFlash
mass memory LAN internal
connection
Mains switch
Prepared for
Mode selector field bus
adapter:
Safety chain - Ethernet I/P
status (option) - Profibus DP

USB
Ethernet
service port
FlexPendant
Hot plug
(option)
ABB Robotics - 5, rev0

Space for I/O units

LAN external
connection (option)
ABB Robotics - 6, rev0

2 Basic
 Module Family Concept, 700-x
Remote panel
Drive module only
700-1

202 cm
137 cm

162 cm
97cm
Dual cabinet Process module on Single cabinet Process module on
Dual cabinet Single cabinet
700-2 700-3
Front access of connections and parts Battery free UPS
ABB Robotics - 7, rev0

Flush sides for reduced floor space 52º (option) without air conditioner
All modules stackable on top of each MTTR < 10 min
other Low profile wheel option
2-3 integrated additional axes
 Panel Mounted Controller, 700-5, -6
Controller modules
without enclosure, to be
mounted in any suitable
enclosure by customer
Available for IRB 140,
340, 260, 1600, 2400
Compact and fully
integrated solution, e.g.
for machine builders
ABB Robotics - 8, rev0
 PMC options, 700-5 and 700-6

Select for
700-5 Panel MultiMove
mounted applications
modules 700-6 Panel Mounted
Drive only

Select when
cooling air is >30C
882-1 Fans or when modules
are mounted
horizontally

881-1 Transformer including:

- rotary mains switch
ABB Robotics - 9, rev0

-secondary circuit breaker

Select when 3x262V and

230V is not available
700-x includes EMC line filter
 PMC limitations, 700-5
IRC5 options listed are not available together with Panel Mounted versions. Most of them are
related to encapsulation. PMC is not intended for ArcWelding applications

16-1 Customer signals connection in cabinet (floor cable 716-726 Internal I/O and gateway units
available) 727-x 24V 4/8/16A (24V 4A for external mountion is
271-1 Position switch connection in cabinet (floor cable available)
available) 730-1 DeviceNet on connector plate
429-1 UL/CSA (UL recognized –UR lable - as standard) 731-2 Safety external connector (internal 731-1
129-1 EU EMC (the mains filter comes always with the drive included)
module) 671-673 IMM interface
769-x Mains voltage (multi tap transformer available as option 733-1 Operator’s panel on cabinet
881-1)
737-1 Status LEDs on front
752-x Mains connection type
753-766 Drives for additional axes
742-x Mains switch (rotary switch included with transformer
option 881-1) 757 SMB for additional axes
743-1 Circuit breaker for rotary switch 761-x Extension cables between modules
744-1 Door interlock 767-1 Duty Time Counter
708-x Room temperature (encapsulation internal temp. max. 758-1 Wheels
45°C) 736-x Service outlet
ABB Robotics - 10, rev0

764-x Cooling air filter 810-1 Electronic Position Switches

741-1 Cabinet connector cover 810-2 SafeMove
829-1 Protection bar 768-x Empty cabinet
707-1 Ethernet on connector plate 715-1 Installation kit
714-1 RS232 to RS422 converter
 Transformer for PMC, 881-1

262V robots
IRB 140 - 2400
200V
200V 262V Drive Motors
220V 220V
Servo 3~ system
400V 400V
440V 440V transformer
480V 480V small
500V 230V Power Controller
500V 600V 1~ supply
600V

Select when 3x262V and 230V is not

available

881-1 6 kVA transformer

ABB Robotics - 11, rev0

Including also:
- rotary mains switch
-secondary circuit breaker
 Fans for PMC, 882-1

Select when cooling air is >30C or when

modules are mounted horizontally

882-1 Fan unit (3 fans)

ABB Robotics - 12, rev0
 Prepared for central lubrication, 1070-1
Option for TrackMotion IRBT xx04
- 24V cabinet cabling for the IRBT lubrication pump
- Ensures that 24V power supply is selected
ABB Robotics - 13, rev0

Select when TrackMotion (on own specification form) has been ordered with central lubrication
 UL/CSA, 429-1
The robot with its control system is certified by Underwriters
Laboratories to comply with the Safety Standard ANSI/UL 1740-
1998 “Industrial Robots and Robotic Equipment” and CAN/CSA Z
434-94.
The option is visualized by a “UL” label attached to the cabinet

Other required options:

- Safety lamp on the manipulator arm
- Door interlock
- Operating mode selector limited speed max 250 mm/s
- If optional service outlet 115V must be selected

Mandatory in some US states and Canada

ABB Robotics - 14, rev0
 EU – EMC, 129-1
The option 129-1 consists of a line filter to prevent radio
noice from exit the cabinet. A certifying document
“Declaration by the manufacturer” is supplied which
tells the machine integrator that the robot (part of a
machine) is prepared for CE marking.

Note! The machine builder is responsible for CE-labelling before

taken into operation within EU countries.
ABB Robotics - 15, rev0

Select when the robot is to be

installed within EU
 Mains voltage connection, 769-x
25 A 262V robots Select voltage
fuse IRB 140 - 6400RF depending on customer
16 A slow fuse (K) line voltage
200V
262V Drive
220V 200V Motors (K) = circuit breaker K
220V
Servo 3~ system
400V 400V characteristic (slow)
440V 440V transformer
480V 480V small
500V 230V Power Controller
500V 600V 1~ supply
600V

400 - 480V robots 480V robot

IRB 66xx IRB 7600
25 A slow fuse (K) 25 A slow fuse (K)
400-480V Drive 480V Drive Motors
3~ Motors
system 3~ system
400V 480V
440V 230V Power 230V Power
480V Controller Controller
400V 1~ supply 400V Electronic 1~ supply
Electronic 440V
440V transformer
480V transformer 480V
ABB Robotics - 16, rev0

200V 480V Drive Motors 200V 200V 480V Drive Motors

200V 220V Servo
3~ system 220V 220V Servo 3~ system
400V 400V 400V
220V 440V transformer 440V transformer
500V 480V large 440V 480V large
500V
230V Power Controller 500V 230V Power Controller
600V 500V
600V 1~ supply 600V 600V 1~ supply
 Mains voltage connection, 769-x
To consider at re-connection to other line voltage (cross border sales)
- The 262V robots allows re-connection within 200-600 V
- The IRB 66xx-family allows re-connection within 400-480 V, with servo
transformer 200-600V.
- The IRB 7600 needs servo transformer for re-connection.
Note! Type lable has to be modified accordingly (order a new)
ABB Robotics - 17, rev0

Example: Change from 400V to 480V in a

262V robot
 Mains connection Cable gland, 752-1
Basic option – no connector means low cost B

The customer power cable is routed via

the cable gland (A) through a tube (C) up
to the mains switch (B).
Protective grounding PE (green/yellow
cable) is connected directly to structure at C
(D).

D
ABB Robotics - 18, rev0

A
 Mains connection 6HSB 6p+PE, 752-2
Select when a quick power connection in cabinet end is desired
Saves installation time and time for replacing cabinet

The customer cable connector (Harting) is included

Compared to 752-1 the internal cable is already
routed to the mains switch inside the cabinet.
Mains connection
“6HSB 6p+PE”
ABB Robotics - 19, rev0
 Mains switch, 742-1, 743-1, 744-1
Basic selection
Additions to rotary switch
744-1 Door interlock
A mechanical latch prevents door
opening when the switch is in ON -
position.
Required by
1) UL
or
2) customer requirement
ABB Robotics - 20, rev0
742-1 Rotary switch
744-1
743-1 Circuit breaker
Acts as an overload protection of
drive module cabling. Interrupt
capacity see table below.
743-1
Selected only when customer
fuses are >35A. Not needed
for 16 – 25A (normal case)
(customer fuse max. 80A due to
internal cabling AWG10, 6 mm2)
 Mains switch Flange disconnect, 742-3
742-3 Flange disconnect
Customer requirement

Option only valid for Single cabinet

Includes
- Circuit breaker
Acts as an overload protection
- Option 752-2, 6HSB mains conn.
of drive module cabling.
- Door interlock (similar to 744-1) Interrupt capacity see table
Can not be combined with below.

- Option 129-1 EMC filter (space conflict)

- Additions to rotary switch 743-1, 744-1
ABB Robotics - 21, rev0

(customer fuse max. 80A due to

internal cabling AWG10, 6 mm2)
 Room temperature 45C, 708-1

Internal air circulating External air

Main computer fan

Panel board fan
Control section fan

Basic selection allows room

temperature up to 45C

Drive system
IRB 140-4400 2 fans
IRB 6400RF-7600 3 fans
ABB Robotics - 22, rev0
 Room temperature 52C, 708-2

Internal air circulating External air

Main computer fan

Control section fan

Heat exchanger inside fan
(panel board fan moved Heat exchanger added
compared to 45C)

Axis computer fan

Select when room temperature

is expected to be higher than
45C but lower than 52C

Drive system
IRB 140-4400 4 std fans
IRB 6400RF-7600 4 fans with
ABB Robotics - 23, rev0

increased capacity
 Cooling air filter, 764-x
Basic delivery
Ducts and fans are exposed to cooling air
and are designed to reduce the need for
maintenance in most applications

Option 764-1. Moist particles are prevented from

entering the air ducts and fans by metal mesh filter.

Select when cooling air contains moist

particles > 0.5 mm

Option 764-2. Moist particles are prevented from

entering the air ducts and fans by polymeric filter
ABB Robotics - 24, rev0

Select when cooling air contains moist dust

 Cabinet connector protection, 741-1
Prevents front connectors from kick damage
Maintains the clean IRC5 design

One metal cover per cabinet

ABB Robotics - 25, rev0
 Warranty – standard products, 438-x
For all orders placed at the PRU from January 1st 2006.
The standard warranty is 18 months after the date of dispatch from the
PRU
The warranty covers design and product defects in material and/or
workmanship
Equivalent parts will replace parts and material subject to warranty
The PRU covers the cost for a part and a fixed compensation according to
set rates
The PRU covers no other costs
Maximum 6 months postponed warranty starting from shipment date PRU + Option 438-1.
Warranty commences automatically after 6 months or from activation date of standard
warranty. (see BA Warranty Rules).
438-1 Standard Warranty
438-2 Standard + 12 Months
ABB Robotics - 26, rev0

438-4 Standard + 18 Months

438-5 Standard + 24 Months
438-6 Standard + 6 Months
438-7 Standard + 30 Months
438-8 Stock warranty
 Warranty – application products, 438-x

For all orders placed at the PRU from January 1st 2006.
PRU do not cover warranty on application products without prior written
agreement
There is no way to guarantee application products until after the moment of
installation and/or programming
Warranty on application products can only start after an inspection
This checklist inspection belongs to the specific application product
ABB Robotics - 27, rev0
 Warranty – parts deliveries

The PRU grants twelve (12) months of warranty on the delivered parts
The warranty covers design and product defects in material and/or workmanship
Equivalent parts will replace parts and material subject to warranty
The PRU covers the cost for a part and no other costs.
ABB Robotics - 28, rev0
 Warranty - software, 438-x

The warranty for software covers only software products delivered by

the PRU
Any additional software for equipment or application, added by LDU,
Lead Center or third party, is not part of the PRU software warranty
The warranty for software ends with the warranty for the complete
system
The software warranty covers only the revision, which is listed in the
WebConfig tool at delivery from PRU. An upgrade or update during the
warranty period will be limited to any remaining warranty period for the
same software previously installed on the system
Each party will carry their own cost related to the diagnostic (fault
tracing) efforts of a product defect resulting in warranty case
ABB Robotics - 29, rev0
 Warranty – LDU responsibility, 438-x

Problem ownership and execution of warranty service of PRU products

Reporting warranties in webconfig and proper warranty reporting
Any distance costs beyond the standard fixed sum compensated by the PRU
Warranty conditions they have agreed upon with their customers, which differ
from those covered by the PRU, and for the resulting extra costs
All costs of special deliveries
Proper handling and packing according to separate packing instructions.
ABB Robotics - 30, rev0
 Remote Service enabled, 890-1
Service box connected to the main computer.
Cabling to an external magnetic antenna (included).

ABB Service Engineer

Note!
- ABB Robotics Response Package subscription
required for operation The service box is
ABB Robotics - 31, rev0

- GPRS communication has to be available located at the floor

- Max 52C inside cabinet
ABB Robotics - 32, rev0

3 Floor cables
 Manipulator cables, 210-x

Customer requirement

Together with Panel Mounted

Controller the 7 m cables for IRB
140 and IRB 340 are prepared for
ABB Robotics - 33, rev0

internal connection also in cabinet

end.

Measurement cable Motor cable

 Floor cables for parallel signals, 94-x
The parallel signals option requires selection in two steps
1. Selection of connection point
1a - if connection to screw terminals inside cabinet, select option16-1,
otherwise the customer provides cable (1b) to customer cabinet
2. If 1a, select length of floor cables
- parallel signals, option 94-x

Select when there

is need for
1a communication
Tool
with arm tool

For internal
arm cabling,
see resp. IRB
1b
ABB Robotics - 34, rev0

Industrial connectors in both ends

Note 1 For IRB 140 the floor cable is always

included. No industrial connector in manipulator end. Customer
2 cabinet
Note 2 For IRB 360 the floor cable 94-x and cabinet
harness 16-1 are mandatory when 218-1 is selected (PLC)
 DressPack floor cables for arm communication
16-1, 90-x, 92-x, 94-x, 455-x
The arm communication option requires selection in two steps
1. Selection of connection point
1a - if connection to screw terminals inside cabinet, select option16-1,
otherwise the customer provides cable (1b) to customer cabinet
2. If 1a, select bus or not bus and length of floor cables
- parallel signals,455-1, cable length 94-x
- parallel and bus, 455-4, cable length 90-x (DeviceNet) or 92-x (Profibus),
fieldbus is connected to the master board Select when there
is need for
communication
with arm tool
Tool
For DressPack
details (455-x), see
1a fieldbus resp. IRB

1b

1a
ABB Robotics - 35, rev0

Industrial connectors in both ends

Customer
2 cabinet
455-x defines the type of cables in DressPack 798-x, 780-x, etc. (PLC)
 SpotPack Basic floor cables 94-7, -8

Select together with

SpotPack Basic

For SpotPack Basic

details, see resp. IRB

Terminals inside
Spot Welding cabinet

94-7 7 m
94-8 15 m
ABB Robotics - 36, rev0

No industrial connectors. The cables are

routed via cable glands in both ends
Terminals inside
connection box
 Cable length pos switches axis 1-3, 273-x, 274-x
The position switch cabling requires selection in two steps
1. Selection of connection point
1a - if connection to screw terminals inside cabinet, select option 271-1,
otherwise the customer provides cable (1b) to customer cabinet
2. If 1a, select length of floor cables
- option 273-x (axis 1) or 274-x (axis 2 & 3)

Additional selection when mechanical

position switch is selected on IRB 6600,
1a 6650S and 7600

1b
ABB Robotics - 37, rev0

Customer
2 cabinet
(safety PLC)
ABB Robotics - 38, rev0

4 Control module
 FlexPendant, 701-x
701-1 10 m cable. Mounting kit included.
701-3 30 m cable. Option 701-1 plus a separate 30 m
cable. The cable replacement is an easy operation (two
screws and two connectors at the FlexPendant back)

Selected in most cases.

It is possible to let several robots share
one FlexPendant, see options 702-x

Mounting kit.
Cable hook

Holder

Holder plate
ABB Robotics - 39, rev0

for free location

 Connector plug, 702-1
The option consists of a jumper connector to close the
safety chains (E-stop) when to disconnect the FlexPendant.
Available also with remote operator’s panel
Disconnection stops the robot.

Mandatory when FlexPendant is not selected.

- enables storing the FlexPendant away from
dirty environment
- enables one FlexPendant for several robots
ABB Robotics - 40, rev0

Connector plug
 Hot plug, 702-2
The option consists of contacts which temporarily can
override the E-stop. For permanent jumpering a connector
plug 702-1 is included
Available also on remote operator’s panel.

The FlexPendant can be disconnected and reconnected

without affecting the program execution
- enables storing the FlexPendant away from dirty
environment White button
- enables one FlexPendant for several robots

How to use:
1. Press the white button (warning flash starts)
2. Disconnect the FlexPendant
3. Attach the connector plug
4. Release the white button (warning flash stops).
ABB Robotics - 41, rev0

Connector plug
 Operator’s panel protection, 829-1
Side bar to protect key switch and
FlexPendant connector
Does not hide the E-stop button

Select when there is a risk for

damage, for example near
transport areas
ABB Robotics - 42, rev0
 FlexPendant languages, 644-x, 645-x
English is basic language
Two more languages can be stored in the FlexPendant
Select among 13 different
- 644-x first additional
- 645-x second additional

Customer requirement

When switching to another language, all buttons, menus and dialogs will use the new
language. RAPID instructions, variables, system parameters, and I/O signals are not affected.
Changing language
1. On the ABB menu, tap Control Panel.
2. Tap Language.
A list of installed languages is displayed.
3. Tap the language that you want to change to.
4. Tap OK. A dialog box is displayed. Tap Yes to proceed and restart the FlexPendant.
ABB Robotics - 43, rev0

The current language is replaced by the selected one. The restart takes approx. 1 min.

Changing to new set of languages possible in System Builder within

RobotStudioOnline
 Ethernet on connector plate, 707-1

Option 707-1 LAN (Local Area Network) port on

main CPU as standard

Select when the robot need quick disconnect

and reconnect to the factory network
ABB Robotics - 44, rev0

Recommended cable connector

Harting # 0945115110000
 Field bus master interface – Overview
3rd party
Profibus DP: slaves mounted
Main CPU externally (or
bus connected directly
to PCI board Master internally)
connector
4 PCI slots
Customer requirement

ABB or 3rd party slaves

mounted internally
or externally
ABB Robotics - 45, rev0

DeviceNet:
DeviceNet is bus connected via connector at front or
recommended as in the harness behind (1 channel) or
a complete offer directly to PCI board connector.
from ABB 1, 2 or 4 channels (buses) selectable
 Field bus slave interface – Overview
Profibus DP:
bus connected directly directly to PCI
Main CPU board Slave connector

Ethernet/IP or Profibus DP slave:

bus connected directly to the bus
adapter front

Allen-Bradley RIO or Interbus:

bus connected via internally or
externally mounted gateway unit

Customer
master
ABB Robotics - 46, rev0

Customer requirement
DeviceNet:
bus connected via connector at front or
in the harness behind or directly to PCI
board connector
 DeviceNet m/s single channel, 709-1
DeviceNet board One channel, option 709-1
IRC5 one 1-connector board
Alternative connections as shown in red
Main CPU
Can handle both master and slave
functionality in the same bus

Recommended as a
complete offer from ABB

Int. I/O units 716-1, 717-2, 718-2

Alt. ext. I/O units,

ABB 816-1, 817-2, 818-2

Connector or 3rd party
on front,
730-1
ABB Robotics - 47, rev0

Alt. connector inside

on harness, available when internal
I/O units are selected
 DeviceNet m/s dual & 4 channels, 709-2, -4
Two channels, option 709-2
DeviceNet board
IRC5 one 2-connector board
Four channels, option 709-4
Main CPU
two 2-connector boards
Ch 2-4 connected to PCI board front in green

Two channels offer Four channels offer

possiblity for extended separation
different baudrates (special customers)

Int. I/O units 716-1, 717-2, 718-2

Alt. ext. I/O units,

ABB 816-1, 817-2, 818-2
or 3rd party
Connector
on front
ABB Robotics - 48, rev0

Alt. connector inside

on harness, available when internal
I/O units are selected
 Profibus DP m/s interface, 711-1, 285-1
Profibus DP board, 711-1 Customer requirement
IRC5
Customer
Main CPU S master
M

Customer slaves

Customer slaves

285-1 Profibus DP m/s CFG Tool

ABB Robotics - 49, rev0

To configure the 711-1 master part,

use the PC tool.
Note! The tool has not to be
selected with every robot order.
 Fieldbus adapter interface, 840-x
Selected when the robot is to be controlled
Main CPU from a customer Ethernet/IP or Profibus DP PLC.

Customer
master PLC

Ethernet/IP 840-1
or
Profibus DP slave 840-2

The customer bus cable is routed via

cable gland at cabinet connector
ABB Robotics - 50, rev0

plate and connected directly at the

Bus cable entrance bus adapter front.
The adapter capacity is 512 inputs
and 512 outputs.
 Robot Ethernet basic

Main CPU Ethernet communication between

main computer (in control module)
and axis computer (in drive module)
4 PCI slots
ABB Robotics - 51, rev0
 Ethernet to external drives, 710-1
1-3 Drive Modules
Main CPU

4 PCI slots

Cable entrance rear

One Ethernet PCI board with 3 Ethernet
ABB Robotics - 52, rev0

channels for communication with other

drive modules

Selected when
1) MultiMove additional robots
2) Drive Modules for additional motors
 No Ethernet card, 884-1

2 But…..
604-1 Coordinated robots or A positioner which is MultiMove controlled
604-2 Independant robots (Manual Jog) by drive units in main cabinet
does not need a Robot Ethernet card
1 This is the
default rule 3 So…...
884-1 No Robot Ethernet
overrides 710-1

710-1 Robot Ethernet

R type positioner
ABB Robotics - 53, rev0

Main robot,
order item 10
 RS232 to 422 converter, 714-1

An adapter plug added to the serial port COM1 via a

short cable.

The RS422/485 enables a more reliable point to

point communication (differential) over longer
distance, from RS232 = 15 m to RS422/485 = 120 m.
ABB Robotics - 54, rev0

Adapter plug
 DeviceNet I/O units/slaves/nodes

Example of 3rd party supplier

Customer requirement of analog input board:
Wago-I/O-System 750
WAGO Limited +
For external mounting, select 8xx instead of 7xx
ABB Robotics - 55, rev0
 DeviceNet gateway, 721-1, 722-1
DeviceNet board
IRC5 Selected when the robot is to be controlled
from a customer Allen-Bradley or Interbus PLC.
Main CPU
The gateway is connected to the control system
via the DeviceNet fieldbus.

Internal gateway units:

Allen-Bradley RIO 721-1,
Interbus 722-1

External gateway units:

Allen-Bradley RIO 821-1,
Interbus 822-1

Connector Customer
on front master PLC
ABB Robotics - 56, rev0
 DeviceNet gateway, 721-1, 722-1

Customer requirement

For external mounting, select 8xx instead of 7xx

ABB Robotics - 57, rev0
 DeviceNet encoder interface, 726-1

Up to four encoders can be

tracked by the control system,
six when PickMaster is activated.
ABB Robotics - 58, rev0

For external mounting, select 826-1 instead of 726-1

 DeviceNet unit size
The cabinet I/O space is divided in “slots”.
The Single cabinet offers 4 slots, the Dual cabinet offers 6.
Each unit need space according to table below.
To be used for calculation of possible combinations.

Option Type Space need

716-1 16 in/16 out 1
717-2 8 in/8 out/2 analog out 1
718-2 8 in/8 relayout 1
721-1 Allen-Bradley RIO gateway 2
722-1 Interbus gateway 1.3
726-1 Encoder interface 1.3
ABB Robotics - 59, rev0
 Power supply 24V – Single Cabinet, 727-X
Cabinet
Computer

System

Cooling

Brakes

ILIM

8A 2.8A
24V
4A
ABB Robotics - 60, rev0

4A
230V
Trafo
 Power supply 24V – Single Cabinet, 727-X
Cabinet Left over from brakes – basic
Computer = No entry
Small robots: 8A available
System Large robots: 5-6A available
Additional motors will
Cooling reduce further.

Brakes Select extra capacity

depending on the need

ILIM

8A 2.8A
24V
727-3
4A
ABB Robotics - 61, rev0

727-1
4A
230V
Trafo
 Power Supply 24V – Dual Cabinet, 727-X

CM
Computer

System

Cooling

4A 4A
4, 8, 16A
24V 4A 4A

DM

24V
ABB Robotics - 62, rev0

Brakes
230V
Trafo
 Power Supply 24V – Dual Cabinet, 727-X

CM Select when there is need for more than 4A

Computer
The first 4A (727-3) is required if DeviceNet
System is selected to supply the bus

Cooling
727-2
4A 4A
4, 8, 16A
24V 4A 4A

DM
727-3 727-1
24V
ABB Robotics - 63, rev0

Brakes
230V
Trafo
 Power supply 24V – Single Cabinet, 727-X
5.2 – 8A basic
DSQC 609 G4
available on door
Option 727-3
Additional 24V 4A terminal XT31.1 and 5

DSQC 609 G5
G4 and G5 =
Option 727-1
Additional 24V 8A

G2 G4 G5 G2 G4 G5 G6

+24 V 0V
+ -
DSQC 662 G2
Distribution unit
ABB Robotics - 64, rev0

DSQC 661 G1
Power supply unit
 Power Supply 24V – Dual Cabinet, 727-X
DSQC 609 G8 Option 727-3
24V 4A
DSQC 604 G2 G4
(as before)

DSQC 634 G6 Option 727-1

Option 728-1 24V 8A
24V 4A ODVA G4 + G5

G4 G5 G7 G8 G4 G5 G7 G8 G6 Option 727-2
24V 16A
G4 + G5 + G7 + G8

+24 V 0V + -
DSQC 609 G4
24V on floor terminal XT31
DSQC 609 G5
ABB Robotics - 65, rev0

DSQC 609 G7
 DeviceNet power supply 24V, 728-1
Select when
- There is a risk for multiple grounds, e.g. when the bus is distributed to
several places
Single point grounding is required by ODVA
DeviceNet power supply is isolated from ground and the bus can be
single point grounded at any customer selected place
- You must fulfill requirements for Limited Power Source class 2 from NEC
in a simple way
DeviceNet power supply 728-1 output is limited to <100W

Note: if you separate the 4A power supply units (727-x) by connecting each
one to a separate terminal you will also limit each output to <100W.
More work, but fulfills the NEC requirements.
ABB Robotics - 66, rev0
 DeviceNet power supply, 728-1

Option not needed in the following normal cases

Single cabinet
Integrated 24V I/O supply used for bus single grounded at the
cabinet chassis.
Process 24V can be supplied from the same integrated source or
from a separate supply.
Dual cabinet
Any of the options 727-X used for bus single grounded at the
cabinet chassis.
Process 24V can be supplied from the same internal source or
from a separate supply.
ABB Robotics - 67, rev0
 External 24V 4A, 886-1
DSQC 609 For mounting on a cap rail
Option 886-1 Supplied from 230V~
Additional 24V 4A Up to 4 units selectable
Note! Max 20A in total, including internal 24V, if supplied
from IRC5 transformer

Select when you need

- supply of equipment in process cabinet
- supply in Panel Mounted Controller applications
ABB Robotics - 68, rev0
 DeviceNet on front, 730-1
DeviceNet board
IRC5

Main CPU

Select when the robot needs quick

Internal I/O disconnect and reconnect to the factory
units DeviceNet fieldbus

External DeviceNet units

5-pole circular female connector

ABB Robotics - 69, rev0

on front, option 730-1.

Recommended customer male

connector is Brad Harrison type
1A5006-34 or ABB part number
3HAC 7811-1.
 Safety interface, 731-x
Safety internal connection, option 731-1
Screw terminals on panel board for safety interface connection.

Minimum selection, free of charge

Safety external connection, option 731-2

Industrial connector on connector plate for safety interface
connection. Customer part included.

Select when the robot needs quick

disconnect and reconnect to the factory
safety circuitry
ABB Robotics - 70, rev0
 IMM interface, 671-x, 673-x
Selected for quick and safe connection of an
Injection Moulding Machine with
standardized interface.

Required other options:

One digital I/O unit 716-1 (671-2)
One relay I/O unit 718-2 (671-1)
Recommended other options:
Electronic position switches or
(mechanical position switches)

Dedicated safety and I/O signal cabinet cabling

Euromap 67, dual safety channels, 671-2

Euromap 12 and SPI AN116, single safety channel, 671-1

671-1 includes also 671-2
ABB Robotics - 71, rev0

10 m floor cable to IMM, 673-1

15 m floor cable to IMM, 673-2
 Operator´s panel, 733-x, 734-x
Either on the cabinet (733-1) or the remote panel (733-2 or -3)
Emergency stop
Motors on
Operating mode selector
Hot Plug button (option)
FlexPendant connector

Always on the cabinet (733-x)

Mains switch
Safety chain status LEDs (option)
USB connection (basic from November 2007)
Service PC connection (Ethernet)
Operating time counter (option) On Drive
Service outlet 115 or 230 V 200 W (option) Module if
Dual
Cabinet
ABB Robotics - 72, rev0
 Operator´s panel, 733-x, 734-x

Panel on cabinet Panel in a box Panel for built-in

733-1 733-2 733-3
Select remote panel when
- Remote control is desired
- If cabinet is placed on a
ABB Robotics - 73, rev0

balcony to keep operator

panel on floor level
734-x
Note:
For Start/Stop of robot a 15, 22 or 30 m
FlexPendant or external
signals are needed
 Operating mode selector, 735-x

2 modes
3 modes
735-2, -4
735-1, -3

Select 3 modes when full Single channel

speed testing is desired 735-1, -2
(and permitted)
Connector on Basic function to be used
panel board
for mode indication to
customer equipment

Dual channels
Additional contacts 735-3, -4
ABB Robotics - 74, rev0

Connector in Select when safety

cable harness interaction with
customer
equipment
is required
 Status LEDs at front, 737-1

Select when Safety chain status

- to avoid opening the door LEDs 737-1
- you need a rapid way to check status
regardless of actual FlexPendant window

The basic ways to check safety chain status

- Open the door and check the panel board front
- Browse to the safety I/O window on the FlexPendant
ABB Robotics - 75, rev0
ABB Robotics - 76, rev0

5 Drive module
 How to order additional motors
Recommended selection Engineering selections
Buy a complete positioner/track Buy components
Positioner IRB 1600 or ABB Motor unit(s) MU X-list
2400 X-list SMB encapsulated MU X-list
Incl. SMB encapsulated Drive units 2-3 motors IRB X-list
Incl. motors Drive module(s) IRC5 X-list
Track Motion IRBT X-list > 3 motors
Incl. SMB encapsulated Floor cables
Incl. motor 2-3 motors MU X-list

Drive units IRB X-list > 3 motors On request

Floor cables positioner IRB X-list

Alternative when non-ABB motors
Floor cables track IRBT X-list SMB (external 757-x) IRB X-list
Customer
encapsulation
Drive units 2-3 motors IRB X-list
Drive module(s) IRC5 X-list
> 3 motors
ABB Robotics - 77, rev0

Floor cables Customer design

 Additional drives IRB 140-2400, 753-x, 754-x, 755-x
Capacitor

Comes with Recti-

additional drive units fier

Larger rectifier when 6-pack robot drive unit

additional drive units (IRB340 4-pack)

Drive Drive Drive

unit 9 unit 8 unit 7

755-x 754-x 753-x

SMB box
= options size C, 9 Amps 75x-1

size T, 25 Amps 75x-2

M7 M8 M9
ABB Robotics - 78, rev0

size U, 36 Amps 75x-3

For low voltage motors

Selected to supply drive power to additional motors
 Prepared for additional drives IRB 140-2400, 766-1
Capacitor

Recti-
Larger rectifier fier

6-pack robot drive unit

= options

Selected to simplify later upgrade with

drive units for additional low voltage motors
ABB Robotics - 79, rev0
 Additional drives IRB 4400, 770-x, 771-x
Capacitor

Drive Drive Recti-

unit 8 unit 7 fier
Larger rectifier when
additional drive units
771-x 770-x

6-pack robot
drive unit

= options size C, 9 Amps 77x-1 SMB box

size T, 25 Amps 77x-2

ABB Robotics - 80, rev0

size U, 36 Amps 77x-3 M7 M8

Low voltage motors

Selected to supply drive
power to additional motors
 Additional drives IRB 6400RF, 66xx-7600, 77x-4
Capacitor

Drive Drive Recti-

unit 8 unit 7 fier

771-4 770-4

6-pack robot
drive unit

= options size W, 30 Amps 77x-4 SMB box

ABB Robotics - 81, rev0

M7 M8

IRB6400RF low voltage motors

Selected to supply drive
power to additional motors
IRB66xx, 7600 high voltage motors
 SMB for additional motors, 757-x
Selected for customer designed
equipment.

757-1 Serial measurement board as separate unit with battery.

757-2 Serial measurement board as separate unit with battery and cables.
One 700 mm cable with connector fitting the measurement link and
one 1400 mm cable with a 64-pole industrial female connector for
resolver connection.

757-1
ABB Robotics - 82, rev0

Additional cables comes with 757-2

 Drive module additional cables, 761-x
Stacked Selected when drive module is
stacked under a Dual or Single
cabinet (761-1), or separated from
its main cabinet (761-3)

Single Dual

761-1 761-1 761-3 761-1 = 4 m

761-3 = 30 m
Selected at dual cabinet split
- side by side (min. height), 761-1
- separated, 761-3
ABB Robotics - 83, rev0
 Duty Time Counter, 767-1
Time displayed is when robot is in operation (brake released)

Allows hour readings without browsing the FlexPendant

Allows hour readings at power off

How to read Duty Time on the FlexPendant

1. On the ABB menu, tap System Info.
2. Tap Hardware devices.
3. Tap Mechanical Units. Duty Time Counter
4. Tap ROB_1
5. Tap General SIS data.
ABB Robotics - 84, rev0
 Wheels, 758-1
Three wheels on each side with the middle wheel
raised 5mm. By balancing on the middle wheels, the
cabinet can easily be manouvered. The idle position
is on the front and middle wheels.

Select when
- There is a need for quick exchange of cabinet
- There is a need for cleaning accessibility
ABB Robotics - 85, rev0
 Service outlet, 736-x
230 V, option 736-1
115 V, option 736-2
Max. power 200 W

For laptop or similar

Service outlet
ABB Robotics - 86, rev0

230 V 115 V
 Axis computer plus, 738-1

Compared to the standard axis computer, the plus

variant is prepared for an additional card used
together with a Force Control sensor. The preparation
means a more powerful processor and space for a
PMC board.

The option is required for the Force Control options

- RobotWare Assembly FC
- RobotWare Machining FC

Axis computer
ABB Robotics - 87, rev0
 Restricting robot working range
Mechanical stops (option)
Available for main axes on large robots
Visible hardware safety
Limit switches (basic, acts as an E-stop)
A controller function which is not used by robot
axes
Mechanical position switches (option)
Not available for wrist axes Safe outputs
Only available for IRB 6600/6650S/7600 Customer
Electronic position switches (option) safety PLC
Available for all robot axes General or
Available for all IRB robots Auto stop or
except IRB 360 safety relay
Hardware and software certified by
authorized body
Software limits (included in basic)
ABB Robotics - 88, rev0

Available for all axes

Available for all robots
Not intended for safety functions
 Electronic Position Switches, 810-1
Can be selected for many reasons:
Replacing mechanical switches
Fully integrated in cabinet
Maintenance free
Increased flexibility
Easy to set up
Easy to replace a robot in production
Enabling more compact mechanical units
Suitable in dirty environment

Position supervision
computer 810-1
(behind the axis
X
ABB Robotics - 89, rev0

computer)
No more cams

Synchronization Switch
Axis computer to be added by customer
 SafeMove, 810-2 (on request until R08.2)

Position supervision
computer 810-1
(behind the axis
ABB Robotics - 90, rev0

computer)

Synchronization Switch
Axis computer to be added by customer
ABB Robotics - 91, rev0

7 Process
 DressPack floor cables for arm communication
16-1, 90-x, 92-x, 94-x, 455-x
The arm communication option requires selection in two steps
1. Selection of connection point
1a - if connection to screw terminals inside cabinet, select option16-1,
otherwise the customer provides cable (1b) to customer cabinet
2. If 1a, select bus or not bus and length of floor cables
- parallel signals,455-1, cable length 94-x
- parallel and bus, 455-4, cable length 90-x (DeviceNet) or 92-x (Profibus),
fieldbus is connected to the master board Select when there
is need for
communication
with arm tool
Tool
For DressPack
details (455-x), see
1a fieldbus resp. IRB

1b

1a
ABB Robotics - 92, rev0

Industrial connectors in both ends

Customer
2 cabinet
455-x defines the type of cables in DressPack 798-x, 780-x, etc. (PLC)
 SpotPack Basic floor cables 94-7, -8

Select together with

SpotPack Basic

For SpotPack Basic

details, see resp. IRB

Terminals inside
Spot Welding cabinet

94-7 7 m
94-8 15 m
ABB Robotics - 93, rev0

No industrial connectors. The cables are

routed via cable glands in both ends
Terminals inside
connection box
 Process module, 768-1, 768-2 and 715-1

Two sizes Empty cabinets are available:

- 768-1 small (H=720mm), mechanically based 768-1
on Dual cabinet control module

- 768-2 large (H=970mm), mechanically based

on Single cabinet.

Select when there is need for extra space for

customer equipment in a cabinet with the same
look and feel as the IRC5.

Additional option:
- Installation kit 815-1, consists of
various brackets and plates to simplify
mounting without hole drilling.

815-1 also includes an

ABB Robotics - 94, rev0

EMC cable gland for

multi cable entrance.

Parts from 815-1 fitted inside 768-2

 Stand-alone controller
Spec form
ABB Robotics - 95, rev0
 Stand-alone controller, 435-99, 751-x, 823-1
435-99 Means that no kinematic or dynamic model of an
IRB will be used.

Drive system size Voltage Motors

751-2 IRB 1600, 2400 low 6
751-4 IRB 340 low 4
751-3 IRB 4400 low 6
751-5 IRB 6600 high 6
751-8 IRB 6400R low 6

823-1 Drive units 4 and 6 disabled. A 4 motor price

reduction by software limitation. Available
for size 4400, 6400R, 6600.

Selected for a customer designed Connection of motors Connection of SMB

ABB Robotics - 96, rev0

mechanical structure. Motors are

recommended to be selected from
the ABB Motor Unit range Drive units for further motors (2-3) can be added as for an IRB
 Stand-alone controller, 751-x

Drive unit type Rated current

751-2 2*E, 2*C, 2*B 2*12, 2*9, 2*5.5
751-4 3*E, 1*C 3*12, 1*9
751-3 3*T, 3*G 3*25, 3*16.5
751-5 3*W, 3*V 3*30, 3*14.5
751-8 3*W, 3*V 3*30, 3*14.5

Connection of motors Connection of SMB

ABB Robotics - 97, rev0

Drive units for further motors (2-3) can be added as for an IRB