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

Revision Description
- First edition

4 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:
• 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)

3HAC021313-001 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:
• Robot fundamentals (describing the fundamental aspects, functions, concept and
similar, of a robot system to provide a basic understanding of the robot system)

6 A 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 A 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:
• 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.

8 A 3HAC021313-001
 1 Reference information, IRC5
1.3. Unit conversion

1.3. Unit conversion

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

Quantity Units
Length 1m 3.28 ft 39.37 in
Weight 1 kg 2.21 lb
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.738 lbf
Moment 1 Nm 0.738 lbf-tn
Volume 1L 0.264 US gal

3HAC021313-001 A 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.

Tightening torque (Nm)

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

10 A 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 A 11
1 Reference information, IRC5
1.6. Standard toolkit, IRC5

1.6. Standard toolkit, IRC5

General
All service (repair, maintenance and installation) instructions contain lists of tools required
to perform the specified activity. All special tools, i.e. all tools that are not considered
standard as defined below, are listed in their instructions respectively.
This way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.

Contents

Tool 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

12 A 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 Note

Operator’s manual - IRC5 3HAC 16590-1
with FlexPendant

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.

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

3HAC021313-001 A 13
1 Reference information, IRC5
1.7. Document references

Document name Document ID

Product manual, IRB 7600 3HAC 022033-001
Product manual, IRB 940 3HAC 022054-001

14 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 A 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 A 17
2 Spare Parts
2.2. Spare Parts IRC5, Control module

2.2. Spare Parts IRC5, Control module

Control cabinet

xx0400001234

Spare parts

Pos Spare part number Description Note

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 DSQC 615
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

18 A 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
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

3HAC021313-001 A 19
2 Spare Parts
2.2. Spare Parts IRC5, Control module

Computer unit

xx0400001236

Spare parts

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

20 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

Spare part
Pos Description Info
number
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

3HAC021313-001 A 21
2 Spare Parts
2.3. Spare Parts IRC5, Drive module

Spare part
Pos Description Info
number
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 DSQC 626
supply
G1 3HAC020466-001 Drive system power DSQC 627
supply
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
FlexPendant
3HAC12929-1 FlexPendant with cable 10m
3HAC11266-1 FlexPendant Cable 10m
3HAC12929-4 FlexPendant with cable 30m
3HAC11266-4 FlexPendant Cable 30m

22 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 A 23
3 Circuit Diagram
3.1. Introduction

24 A 3HAC021313-001
 1 2 3 4 5 6 7 8

EPLAN

The information in this document is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

In no event shall ABB be liable for incidental or consequential damages arising from use of this document
or of the software and hardware described in this document.

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

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

© Copyright 2004 ABB All right reserved.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
ABB Automation Technologies AB

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Robotics
SE-721 68 Västerås
Sweden

Latest revision: Lab/Office: Status: Plant: = DOKUMENTE

Approved Location: + DKB
EPLAN Sublocation: +
Title page Document no. Rev. Ind Page 1
Next 2
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

EPLAN

Phone :

Customer :
Robot serial number(s) :
Drawing number : 3HAC020538-002_Control
Drawing version :
Manufacture : 2004-09-28
Type :
Type of installation :
Control cabinet :
Mains voltage :
Supply :
Control voltage :
Year of construction :

Project start : 2004-05-05

Project manager :
Last revision :

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Designed by : jsundin1

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Designed date : 2004-09-28
Number of pages : 42
:

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 1 2 3 4 5 6 7 8

Table of contents DIN_INV_30_1

Plant Location Page Page description Page supplementary field Date Editor
DOKUMENTEDKB 1 Title page Approved 2004-09-24 jsundin1
DOKUMENTEDKB 2 Title page Approved 2004-09-24 jsundin1
DOKUMENTEINV 3 Table of contents: (1 - 30) Approved 2004-09-24 jsundin1
DOKUMENTEINV 4 Table of contents: (31 - 42) Approved 2004-09-24 jsundin1
CM ORT 5 BLOCK DIAGRAM Approved 2004-09-24 jsundin1
CM ORT 6 VIEW OF CONTROL MODULE Approved 2004-09-24 jsundin1
CM ORT 7 MAINS CONNECTION Approved 2004-09-24 jsundin1
CM ORT 8 POWER SUPPLY Approved 2004-09-24 jsundin1
CM ORT 9 OPTION: POWER SUPPLY Approved 2004-09-24 jsundin1
CM ORT 10 EMERGENCY STOP Approved 2004-09-24 jsundin1
CM ORT 11 RUN CHAIN OPERATING MODE SELECTOR, 3 MOD Approved 2004-09-24 jsundin1
CM ORT 12 EMERGENCY STOP Approved 2004-09-24 jsundin1
CM ORT 13 RUN CHAIN Approved 2004-09-24 jsundin1
CM ORT 14 RUN CHAIN OPERATING MODE SELECTOR, 2 MOD Approved 2004-09-24 jsundin1
CM ORT 15 RUN CHAIN EXT OPERATING MODE SELECTOR, 2 Approved 2004-09-24 jsundin1
CM ORT 16 RUN CHAIN EXT OPERATING MODE SELECTOR, 3 Approved 2004-09-24 jsundin1
CM ORT 17 FPU, FLEXPENDANT Approved 2004-09-24 jsundin1
CM ORT 18 OPTION: EXTERNAL CONNECTIONSYSTEM SIGNAL Approved 2004-09-24 jsundin1
CM ORT 19 VIEW OF COMPUTER UNIT Approved 2004-09-24 jsundin1
CM ORT 20 CABLING IN COMPUTER UNIT Approved 2004-09-24 jsundin1
CM ORT 21 CABLING IN COMPUTER UNIT Approved 2004-09-24 jsundin1
CM ORT 22 COMPUTER UNITCOOLING Approved 2004-09-24 jsundin1
CM ORT 23 MAIN COMPUTER Approved 2004-09-24 jsundin1
CM ORT 24 ROBOT COMMUNICATION CARD Approved 2004-09-24 jsundin1
CM ORT 25 ROBOT COMMUNICATION CARD Approved 2004-09-24 jsundin1

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
CM ORT 26 PROFIBUS DP M/S Approved 2004-09-24 jsundin1
CM ORT 27 INTERBUS M/S Approved 2004-09-24 jsundin1
CM ORT 28 DEVICENET ADAPTER Approved 2004-09-24 jsundin1
CM ORT 29 DEVICENET ADAPTER Approved 2004-09-24 jsundin1
CM ORT 30 DUAL RS232 CARD Approved 2004-09-24 jsundin1

Latest revision: Lab/Office: Status: Plant: = DOKUMENTE

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EPLAN Sublocation: +
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 1 2 3 4 5 6 7 8

Table of contents DIN_INV_30_1

Plant Location Page Page description Page supplementary field Date Editor
CM ORT 31 ETHERNET CARD Approved 2004-09-24 jsundin1
CM ORT 32 DIGITAL PART OF COMBI I/O ANDDIGITAL I/O Approved 2004-09-24 jsundin1
CM ORT 33 DIGITAL I/O UNIT Approved 2004-09-24 jsundin1
CM ORT 34 COMBI I/O UNIT Approved 2004-09-24 jsundin1
CM ORT 35 RELAY I/O UNIT Approved 2004-09-24 jsundin1
CM ORT 36 RELAY I/O UNIT Approved 2004-09-24 jsundin1
CM ORT 37 RELAY I/O UNIT Approved 2004-09-24 jsundin1
CM ORT 38 ANALOGUE I/O UNIT Approved 2004-09-24 jsundin1
CM ORT 39 REMOTE I/O UNIT Approved 2004-09-24 jsundin1
CM ORT 40 INTERBUS SLAVE Approved 2004-09-24 jsundin1
CM ORT 41 PROFIBUS DP SLAVE Approved 2004-09-24 jsundin1
CM ORT 42 ENCODER UNIT Approved 2004-09-24 jsundin1

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = DOKUMENTE
Approved Location: + INV
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Table of contents: (31 - 42) Document no. Rev. Ind Page 4
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Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

230V
X20

Option Q2
Service outlet

XT16

T3 G3 G2
Option Option Option
AC Devicenet PS Customer PS Customer PS
Ultra cap
G6 G4 G5
DC
AC AC AC
DC DC DC
F5
A21 A3
Panel Computer
F4 module
board
Earth
fault
prot.

S21 I/Ox

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Control I/O

We reserve all rights in this document and in the information contained therein.Reproduction, use or
X22 panel FPU unit
Service
outlet

Drive
Field bus
Drive
Ethernet service
USB
LAN

Customer Customer
connection connection

Latest revision: Lab/Office: Status: Plant: = CM

Approved Location: + ORT
EPLAN Sublocation: +
BLOCK DIAGRAM Document no. Rev. Ind Page 5
Next 6
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 42
 0 1 2 3 4 5 6 7 8 9

A21 (Panel Board)

G4 X4 X3
G2
G5 G3 A3
G6 if not G5
if G5 G6 in I/O unit.
Epwr
X18 EN1
X5
Q2 AS1
X20 AS2
GS1
X7 X18 X6 GS2
S21.3 X11 SS1
SS2
(emergency pb) ES1
X1
ES2
S21.2
(motor on pb) X9 X2

S21.1
(mode selector)
X12 X17
X15 X14
X10
X22
A22.X1
(opt service outlet)

X20 I/O2

I/O4 I/O1
X28
I/O3

XS58
XS13 XS3
XS8 XT58
XS5
XT8
XS17
XT6

XT5
=CM+ORT/5 =CM+ORT/7
02 2004-09-24 Date 2004-09-28 EPLAN VIEW OF CONTROL MODULE + CM
Edit. jsundin1 ORT
Page
Check. CM Approved 3HAC020538-002_Control Page 6
Modification Date Name Standard Origin Crea. for Crea. by 42 Pg.
 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
Latest revision:
1

Prepared by, date:

-X16

/8.3 / -230V AC1 -181 AWG16 BK

/9.2 / -230V AC1 -308 AWG16 BK
DRIVE MODULE

/9.5 / -230V AC1 181

CONTROL MODULE

/9.7 / -230V AC1 181

2

-Q2
-X20
-X25

-173 AWG16 BK -171 AWG16 BK 230V AC1

Approved by, date:
1
1

L1

T1

-174 AWG16 BK -172 AWG16 BK 230V AC2

2
2

L2

T2
L3

T3
GND
GND

/8.3 / -230V AC2 -182 AWG16 BK

/9.2 / -230V AC2 -309 AWG16 BK
3

/9.5 / -230V AC2 182

/9.7 / -230V AC2 182
4

EPLAN
Lab/Office:
-187 AWG16 BK
-186 AWG16 BK
5

MAINS CONNECTION
OPTION:
6

-F5
SERVICE OUTLET

CIRCUIT BREAKER
-T3

BREAKER

=CM
+X22
EARTH FAULT
230V

-F4
AWG16 BK

Status:
3
115V
7

-183
3

Document no.
AWG16 BK

Approved
-184

2
1
-185 AWG16 BK 0V

4
3
4
2

Plant:
Location:
Sublocation: +
= CM
8

3HAC020538-002 02
+ ORT

Next 8
Rev. Ind Page 7

Total 42
 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
Latest revision:
1

Prepared by, date:

+G2
=CM

-X2

/10.2 / -24V SYS -250 BU

1

/10.2 / -0V SYS -251 BU

2
2

/10.2 / -24V COOL -252 BU

3
24V SYS

PANEL BOARD
24V COOL

/10.2 / -0V COOL -253 BU

4
PROCESS POWER SUPPLY

Approved by, date:

-X1

-181 AWG16 BK -230V AC1 / /7.1

1

-182 AWG16 BK -230V AC2 / /7.3

5

AC -INPUT
3

-X3

/20.2 / -24V PC -301 BU

3

/20.2 / -24V PC -302 BU

2

UNIT
24V PC

COMPUTER /20.2 / -0V PC -303 BU

3

/20.2 / -0V PC -304 BU

4
4

+G3

EPLAN
=CM -X1
-X4

+
1
1

+
2
2

NC

Lab/Office:
3
3

NC
4
4

+
5
5
5

ULTRA CAP
6
6

-
7
7
ULTRA CAP

8
8

+Sense

POWER SUPPLY
9
9

NC
-
10
10
6

-X5
/23.6 / -USB +5V AWG24 RD

1
/23.6 / -USB-BP2 AWG28 WH

MAIN
USB
/23.6 / -USB-BP2 AWG28 GN

COMPUTER
Status:
/23.6 / -USB_GND AWG24 BK
7

Document no.
Approved
Plant:
Location:
Sublocation: +
= CM
8

3HAC020538-002 02
+ ORT

Next 9
Rev. Ind Page 8

Total 42
 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
Latest revision:
1

+G6
=CM

Prepared by, date:

DEVICENET
POWER SUPPLY

-X2
-X1

/29.1 / -+24V devicenet -308 AWG16 BK -230V AC1 / /7.2

AC
L

-309 AWG16 BK -230V AC2 / /7.3

DC

-
N
2

/29.1 / -0V devicenet

-

Approved by, date:

/32.1 / -+24V devicenet

/32.1 / -0V devicenet
GND

/35.1 / -+24V devicenet

/35.1 / -0V devicenet
3

/38.1 / -+24V devicenet

/38.1 / -0V devicenet
/39.1 / -+24V devicenet
/39.1 / -0V devicenet
/40.2 / -+24V devicenet
/40.2 / -0V devicenet
4

/41.1 / -+24V devicenet

EPLAN
/41.1 / -0V devicenet
/42.1 / -+24V devicenet
/42.1 / -0V devicenet

Lab/Office:
=CM
+G4
POWER
SUPPLY
5

-X2
-X1
CUSTOMER

24V I/O 181 -230V AC1 / /7.2

AC

1
1

0V I/O 182 -230V AC2 / /7.3

DC

3
5
3

Customer
Connection
24V I/O

2
0V I/O

OPTION: POWER SUPPLY

6

4
=CM
+G5
POWER
SUPPLY

Status:
-X2
-X1
CUSTOMER
24V I/O 181 -230V AC1 / /7.2
7

AC

1
1

Document no.
Approved
0V I/O 182 -230V AC2 / /7.3

DC

3
5
3

Customer
Connection

Plant:
24V I/O

Location:
2
0V I/O

Sublocation: +
4

= CM
8

3HAC020538-002 02
+ ORT

Rev. Ind Page 9

Total 42
Next 10
 1 2 3 4 5 6 7 8

PANEL BOARD
=CM
+A21

-250 BU
-X12
/8.2 / -24V SYS
1
PROCESS /8.2 / -0V SYS -251 BU

POWER 2
/8.2 / -24V COOL -252 BU
SUPPLY
3
/8.2 / -0V COOL -253 BU
4

-X1 -X2 -X10 -209 AWG20

ES1 top -ES FPU 1:A / /17.2
ES2 top 3 5 -211 AWG20 -ES FPU 2:A / /17.2 JUNCTION
3 7 -212 AWG20 -ES FPU 2:B / /17.2 BOARD
8 -210 AWG20 -ES FPU 1:B / /17.2
EXTERNAL 0V 0V 6

EMERGENCY 24V Panel 4 24V PANEL

4
STOP PB

RunCh+
Run CH1 top

RunCh_0V
Run CH2 top 5 EMERGENCY PB
-S21.3
5
-X9 -237 ES panel 1:A 21 22
EMERGENCY ES1OUT:A
STOP OUTPUT 1 ES2 OUT:A 1 17 -238 ES panel 1:A
1 18 -233 ES panel 2:A 11 12
EMERGENCY ES2 OUT:B 13 -234 ES panel 2:A

STOP OUTPUT 2 ES1OUT:B 2 14 -231 ES panel 2:B

2 11 -232 ES panel 2:B
Sep ES2:A RunCh_0V 12 -235 ES panel 1:B
Sep ES1:A 9 RunCh+ 15 -236 ES panel 1:B
9 -ES2 16
-ES1

U U

Sep ES1:B A2 A1
10
Sep ES2:B A1 A2
10
ES2 bottom
EXTERNAL ES1 bottom 7 AWG24
-X11
SUPPLY 0V 7
24V Panel 8 1
8 2 OG -24V_Sig.ref. / /24.5

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
24V PANEL 3 BU

We reserve all rights in this document and in the information contained therein.Reproduction, use or
-RS485+ / /24.5
4 WHBU -RS485- / /24.5 ROBOT COMM.
0V 5 CARD
6 WHBN -0V_Sig.ref. / /24.5
EMERGENCY STOP ES1:int 7
RELAY SIGNALS 6 8
SOFT_ESO
ES2:int
6 ES1 ES2
SOFT_ESI
+ORT/12.6 / -RCH2
+ORT/12.7 / -RCH1

+ORT/12.6 / -RunCh+
+ORT/12.5 / -RunCh_0V

Latest revision: Lab/Office: Status: Plant: = CM

Approved Location: + ORT
EPLAN Sublocation: +
EMERGENCY STOP Document no. Rev. Ind Page 10
Next 11
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

PANEL BOARD
=CM
+A21
-X3 -X10 -205 AWG20
General in1 -24V FPU_POWER / /17.2
1 General in2 1 -206 AWG20 -0V / /17.2 JUNCTION
2 General in3 2 -207 AWG20 -EN1_1 / /17.2 BOARD
3 General in4 3 -208 AWG20 -EN1_2 / /17.2
4 General in5 4 -213 AWG20 -FPU START / /17.2
5 General in6 9
6 General in7
-X6
7 General in8 EN2_1A OPTION
8 0V 7 EN2_1B EXTERNAL
9 +24V 8 EN2_2A ENABLE DEVICE -S21.1.X1 3 2 1 4 7 6 5 8
10 9 EN2_2B
10
-X4
General out1
-X9 MAN FS1
1 General out2 AWG20 -227
-245
-244
-243
-246
-241
-240
-239
-242

2 General out3 8 AWG20 -226 MAN1

3 General out4 7 AWG20 -225 AUTO1
4 General out5 6 AWG20 -223 MAN FS2
OPTION: STATUS 5 General out6 4 AWG20 -222 MAN2
LED ON FRONT 6 General out7 3 AWG20 -221 AUTO2
EXT.MAN2
EXT.MAN1

EXT.AUTO2
EXT.AUTO1

=CM 7 General out8 2

EXT MAN FS2
EXT MAN FS1

MODE
EXT.COMMON2
EXT.COMMON1

+A23 8 0V
SELECTOR
9
-ES2 -S21.1 6 1210 2 4 8 182224 141620
>1
-ES1
5 1 17 13
AWG26
-SUP_ST2 -X2 WHOG
-X20 AWG20 -220 24V panel
1 OG 1 1 AWG20 -224 0V
-SUP_ST1 BU
2 2 RS485+ 5
4 WHBU 4 RS485-
-GS2 WHGN
MOTOR ON PB
5 5 24V DC
GN
-S21.2
3 3
-GS1 WHBN AWG20 -229 MOTON 14 13
6 6 0V
7 BN 7 10 AWG20 -228 24V PANEL
-AS2
8 8 9
AWG20 -230 MONLMP X2 X1
-AS1
19

-ENABLE1
OPTION:
DOOR FAN 52
=CM

+ORT/12.5 / -EN1
+ORT/12.5 / -EN2
+ORT/12.5 / -MAN1
+ORT/12.4 / -MAN2
+E3 M

+ORT/13.3 / -SPEED
1~
- +

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
EXT COMPUTER FAN

We reserve all rights in this document and in the information contained therein.Reproduction, use or
24V PANEL
-X1 2 1 =CM
-X15
OP_COM +E2
OP_MAN 1
-X18 -364 AWG20 BU;BU -361 AWG20
-X18 -X1
3 24V COOL RD
+

2 2 1
OP_AUTO TACHO -362 AWG20 BU BN
2 3 3 2
M
OP_MAN_FS
4 -
FAN 0V -363 AWG20 BU;BU -360 AWG20 BK
1 1 3

Latest revision: Lab/Office: Status: Plant: = CM

Approved Location: + ORT
EPLAN Sublocation: +
RUN CHAIN OPERATING Document no. Rev. Ind Page 11
Next 12
Prepared by, date: Approved by, date: MODE SELECTOR, 3 MODES 3HAC020538-002 02 Total 42
 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
Latest revision:
1

Prepared by, date:

STOP
STOP
STOP
AUTO

GENERAL

SUPERIOR
2

GS2+
GS1+

GS2-
GS1-

SS2-
SS2+
SS1-
SS1+
AS2-
AS2+
AS1-
AS1+
=CM
+A21

3
2
4
6
2
8
3
9
7

11
12

-X6
-X5

5
1
4
5
1
6

Approved by, date:

10

0V
0V
0V
PANEL BOARD

24V PANEL
24V PANEL
24V PANEL

SS2
SS1
AS2
AS1

GS2
GS1
3

SS2
SS1
AS2
AS1

SOFT SS
GS2
GS1
4

SOFT GS

EPLAN
SOFT AS

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

Lab/Office:
5

-EN2 / +ORT/11.4
+ORT/13.3 / -ENABLE2_1 -EN1 / +ORT/11.4
+ORT/13.3 / -ENABLE2_2 -RunCh_0V / +ORT/10.5
+ORT/13.3 / -ENABLE2_3
+ORT/13.3 / -ENABLE2_4
&

EMERGENCY STOP
-RunCh+ / +ORT/10.5
6

&
CH2
+ORT/13.4 / -RCH2 -RCH2 / +ORT/10.6

CH1

Status:
+ORT/13.4 / -RCH1 -RCH1 / +ORT/10.6
7

Document no.
Approved
Plant:
Location:
Sublocation: +
= CM
8

3HAC020538-002 02
+ ORT

Total 42
Next 13
Rev. Ind Page 12
 1 2 3 4 5 6 7 8

CONTROL
PANEL BOARD
MODULE
=CM
+A21
+ORT/12.7 / -RCH1

+ORT/12.6 / -RCH2
-X7
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret Drive
24V PANEL 4 RUN CH2 module1
+ORT/11.4 / -SPEED 3 SPEED A43.X1
5 0V
+ORT/12.5 / -ENABLE2_1 6 ENABLE2_1
7 ENABLE2_1Ret
+ORT/12.5 / -ENABLE2_2 8 AC_ON1
9 0V
+ORT/12.5 / -ENABLE2_3 10

+ORT/12.5 / -ENABLE2_4

-X8
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret
24V PANEL 4 RUN CH2 Drive
3 SPEED module2
5 0V if not used A43.X1
6 ENABLE2_2
7 ENABLE2_2Ret
8 AC_ON1 if not used
9 0V
10

-X14
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret Drive
24V PANEL 4 RUN CH2 module3
3 SPEED A43.X1
5 0V if not used
6 ENABLE2_3
7 ENABLE2_3Ret
8 AC_ON1 if not used
9 0V
10

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-X17
RUN CH1
0V 1 RUN CH1Ret
2
RUN CH2Ret Drive
24V PANEL 4 RUN CH2 module4
3 SPEED A43.X1
5 0V if not used
6 ENABLE2_4
7 ENABLE2_4Ret
8 AC_ON1 if not used
9 0V
10

Latest revision: Lab/Office: Status: Plant: = CM

Approved Location: + ORT
EPLAN Sublocation: +
RUN CHAIN Document no. Rev. Ind Page 13
Next 14
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

PANEL BOARD
=CM
+A21

-X9 -222 AWG20 BU MAN2 -241 OG EXT.AUTO1

-S21.1.X1
3 7
-221 AWG20 BU AUTO2 -240 OG EXT.MAN1
2 6
-226 AWG20 BU MAN1 -245 OG EXT.AUTO2
7 3
-225 AWG20 BU AUTO1 -244 OG EXT.MAN2 OPTION
6 2

MODE SELECTOR
1
-S21.1 1 3 5 7 9 11 13 15

2 .5 6 .5 10 .5 14
5
-224 AWG20 BU 0V -246 OG EXT.COMMON2
5 4
-220 AWG20 BU 24V panel -242 OG EXT.COMMON1
1 8

MOTOR ON PB
-S21.2

-229 AWG20 BU MOTON 14 13

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

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = CM
Approved Location: + ORT
EPLAN Sublocation: +
RUN CHAIN OPERATING Document no. Rev. Ind Page 14
Next 15
Prepared by, date: Approved by, date: MODE SELECTOR, 2 MODES 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

CONTROL EXT. CONTROL PANEL

MODULE
PANEL BOARD
=CM -Ext.A21.X9
-X9 -222 AWG20 MAN2 -241 EXT.AUTO1
-S21.1.X1
+A21
3 3 -221 AWG20 AUTO2 -240 EXT.MAN1 7
2 2 -226 AWG20 MAN1 -245 EXT.AUTO2 6
7 7 -225 AWG20 AUTO1 -244 EXT.MAN2 3
6 6 2
MODE SELECTOR
-S21.1 1 3 5 7 9 11 13 15 OPTION

2 .6 6 .6 10 .6 14

-224 AWG20 0V -246 EXT.COMMON2

5 5 -220 AWG20 24V panel -242 EXT.COMMON1 4
1 1 8
MOTOR ON PB
-S21.2

-229 AWG20 MOTON 14 13

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

EMERGENCY PB
-S21.3
-237 ES panel 1:A 21 22
17 17 -238 ES panel 1:A
18 18 -233 ES panel 2:A 11 12
13 13 -234 ES panel 2:A
14 14 -231 ES panel 2:B
11 11 -232 ES panel 2:B
12 12 -235 ES panel 1:B
15 15 -236 ES panel 1:B
16 16

JUNCTION BOARD
=CM
+A22
-X10 -X3
BN/BK 24V TPU
1 BN/RD 0V 1
2 BN/OG EN1_1 2
3 BN/YE EN1_2 3
4 4
5 5
6 6

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
7 7

We reserve all rights in this document and in the information contained therein.Reproduction, use or
8 BN/GN TPU_START 8
9 9

ROBOT COMMUNICATION CARD

=CM AWG24
-A8 WHOG
-X2
+A32 TD+
3 TD- OG 1
6 RD+ WHGN 2
1 RD- GN 3
2 4

Latest revision: Lab/Office: Status: Plant: = CM

Approved Location: + ORT
EPLAN Sublocation: +
RUN CHAIN EXT OPERATING Document no. Rev. Ind Page 15
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Prepared by, date: Approved by, date: MODE SELECTOR, 2 MODES 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

CONTROL EXT. CONTROL PANEL

MODULE
PANEL BOARD
=CM -Ext.A21..X9
-X9 MAN FS1 EXT.AUTO2
-S21.1.X1
+A21 -227 AWG20 -245
8 8 -226 AWG20 MAN1 -244 EXT.MAN2 3
7 7 -225 AWG20 AUTO1 -243 EXT MAN FS2 2
6 6 -223 AWG20 MAN FS2 -241 EXT.AUTO1 1
4 4 -222 AWG20 MAN2 -240 EXT.MAN1 7
3 3 -221 AWG20 AUTO2 -239 EXT MAN FS1 6
2 2 5
MODE SELECTOR
-S21.1 6 1210 2 4 8 182224 141620 OPTION

.7 .7 .7
5 1 17 13

-224 AWG20 0V -242 EXT.COMMON1

5 5 -220 AWG20 24V panel -246 EXT.COMMON2 8
1 1 4
MOTOR ON PB
-S21.2

-229 AWG20 MOTON 14 13

10 10
-230 AWG20 MONLMP X2 X1
19 19 -228 AWG20 24V PANEL
9 9
EMERGENCY PB
-S21.3

-237 ES panel 1:A 21 22

17 17 -238 ES panel 1:A
18 18 -233 ES panel 2:A 11 12
13 13 -234 ES panel 2:A
14 14 -231 ES panel 2:B
11 11 -232 ES panel 2:B
12 12 -235 ES panel 1:B
15 15 -236 ES panel 1:B
16 16

JUNCTION BOARD
=CM
+A22
-X10 -X3
BN/BK 24V TPU
1 BN/RD 0V 1
2 BN/OG EN1_1 2
3 BN/YE EN1_2 3
4 4
5 5
6 6

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
7 7

We reserve all rights in this document and in the information contained therein.Reproduction, use or
8 BN/GN TPU_START 8
9 9

ROBOT COMMUNICATION CARD

=CM
+A32 AWG24
-A8 WHOG
-X2
TD+
3 TD- OG 1
6 RD+ WHGN 2
1 RD- GN 3
2 6

Latest revision: Lab/Office: Status: Plant: = CM

Approved Location: + ORT
EPLAN Sublocation: +
RUN CHAIN EXT OPERATING Document no. Rev. Ind Page 16
Next 17
Prepared by, date: Approved by, date: MODE SELECTOR, 3 MODES 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

OPTION:
FPU-PLUG

X22.XP1

5
JUNCTION BOARD
6
=CM
+A22 4
FLEXPENDANT
=CM
+FPU EMERGENCY-STOP

-X3 -X1 -K1

/10.7 / -ES FPU 1:A -209 AWG20 BU
5 3
PANEL /10.7 / -ES FPU 2:A -211 AWG20 BU

BOARD 7 5
/10.7 / -ES FPU 2:B -212 AWG20
8 6
/10.7 / -ES FPU 1:B -210 AWG20 BU
6 4
EN-DEVICE
1 -K2
/11.6 / -24V FPU_POWER -205 AWG20 BU
1 12
PANEL /11.6 / -0V -206 AWG20 BU

BOARD 2 2

8
/11.6 / -EN1_1 -207 AWG20
3 7
/11.6 / -EN1_2 -208 AWG20
4 17

/11.6 / -FPU START -213 AWG20 BU

9 11

AWG24

WHOG
-X2
/24.6 / -TD+
1 13
ROBOT COMM. /24.6 / -TD- OG

CARD 2 14
/24.6 / -RD+ WHGN ETH_FPU
3 15

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
GN

We reserve all rights in this document and in the information contained therein.Reproduction, use or
/24.6 / -RD-
6 16

Latest revision: Lab/Office: Status: Plant: = CM

Approved Location: + ORT
EPLAN Sublocation: +
FPU, FLEXPENDANT Document no. Rev. Ind Page 17
Next 18
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

PANEL BOARD
PANEL BOARD
=CM
+A21 =CM
+A21
-X1 -260 OG
-XS/XP3 AWG20 BU
-X5 -272 AWG20 BU
-XS/XP3 AWG20 BU
ES1 bottom 24V PANEL
7 A1 12 C1
-X2 -261 OG AWG20 BU -273 AWG20 BU
ES2 bottom AS1+
7 B1 11 C2
24V PANEL -262 AWG20 BU AS1- -274 AWG20 BU AWG20 BU
8 B2 9 C3
0V -263 AWG20 BU 0V -275 AWG20 BU
8 A2 7 C4
24V PANEL -264 AWG20 BU AWG20 BU AWG20 BU
4 A3 C5
Run CH1 top GS1+ -276 AWG20 BU
5 10 C6
Run CH2 top GS1- -277 AWG20 BU AWG20 BU
5 8 C7
0V -265 AWG20 BU AWG20 BU
4 B3 C8
ES2 top -266 OG 24V PANEL -278 AWG20 BU AWG20 BU
3 B4 6 D1
ES1 top -267 OG AS2+ -279 AWG20 BU
3 A4 5 D2
Sep ES1:A -268 OG AWG20 BU AS2- -280 AWG20 BU AWG20 BU
9 A5 3 D3
Sep ES2:A -269 OG AWG20 BU 0V -281 AWG20 BU
9 B5 1 D4
Sep ES2:B -270 OG AWG20 BU
10 B6 D5
Sep ES1:B -271 OG GS2+ -282 AWG20 BU
10 A6 4 D6
ES1 OUT A -284 OG GS2- -283 AWG20 BU AWG20 BU
1 A7 2 D7
ES1 OUT B -285 OG
2 A8 D8
ES2 OUT A -286 OG
1 B7
ES2 OUT B -287 OG
-X6 AWG20 BU AWG20 BU
2 B8 0V -289
1 A10
SS1- -291 AWG20 BU
2 B10
SS2- -293 AWG20 BU
3 C10
SS1+ -290 AWG20 BU
4 B9

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-292 AWG20 BU

We reserve all rights in this document and in the information contained therein.Reproduction, use or
SS2+
5 C9
24V PANEL -288 AWG20 BU AWG20 BU
6 A9

10

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Prepared by, date: Approved by, date: SYSTEM SIGNALS 3HAC020538-002 02 Total 42
 0 1 2 3 4 5 6 7 8 9

A3 Computer unit

X1 PWR HDD
(green) (yellow) A32 (RCC)

Slot 1 Slot 2 Slot 3 Slot 4 Slot 5

LAN
USB1,2 USB3,4

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

=CM+ORT/18 =CM+ORT/20
02 2004-09-24 Date 2004-09-24 EPLAN VIEW OF COMPUTER UNIT + CM
Edit. jsundin1 ORT
Page
Check. CM Approved 3HAC020538-002_Control Page 19
Modification Date Name Standard Origin Crea. for Crea. by 42 Pg.
 1 2 3 4 5 6 7 8

COMPUTER UNIT
=CM
+A3 COMPUTER POWER SUPPLY
=CM MAIN COMPUTER
+G31 =CM
+A31
-301 BU
-X1 -X1
/8.3 / -24V PC P1
1 V+
PROCESS /8.3 / -24V PC -302 BU

POWER SUPPLY 4
-303 BU
-P1 -J4H1
/8.3 / -0V PC OR +3.3V
2 OR +3.3V 1
/8.3 / -0V PC -304 BU BK GND 2
3 V- RD +5V 3
BK GND 4
RD +5V 5
BK GND 6
MOTHER 7
BOARD
-PSU-X1
GY PWR_OK
POWER 1 8
-PSU-X2
VT +5VSB
1 9
-P1
YE +12V
OR +3.3V 10
BU -12V 11
12
-PSU-X2
BK GND
2 GN PS_ON 13
3 14
-P1
BK GND
BK GND 15
BK GND 16
17
RD +5V 18
RD +5V 19
20

-IDEpwr
-IDEpwr_GND / +ORT/21.2
-IDEpwr_+5V / +ORT/21.2

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 1 2 3 4 5 6 7 8

COMPUTER UNIT
=CM
+A3 MAIN COMPUTER
=CM
+A31
SOLID STATE DRIVE
=CM
+D32 40
-X2 -J6H1
-X1
ATA/IDE
1
+ORT/20.7 / -IDEpwr_GND GND 2
+ORT/20.7 / -IDEpwr_+5V +5V 3
4

OPTION:
HARD DISK DRIVE
=CM
+D31 40
-X2 -J6H1
-X1
1 ATA/IDE
1
GND 2
+5V 3
4

REMARK: P1 & J6H1 CONNECTS TO EITHER D32 OR D31

DEPENDING OF CHOSED OPTION.

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 1 2 3 4 5 6 7 8

COMPUTER UNIT
=CM
+A3
COMPUTER POWER SUPPLY
=CM
+G31

P1

BK GND
YE +12V

CHASSIS BLOWER
-E22

MAIN COMPUTER M
AWG 24
=CM
+

-C2
+A31 BK GND BK
YE +12V 1 RD
-J9H1
2
1
2 WH FAN2_TACH
3

CHASSIS BLOWER
-E23
-J9H2
1 -
2
3
M
AWG 24
+

-C1
BK GND BK
YE +12V 1 RD

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2

We reserve all rights in this document and in the information contained therein.Reproduction, use or
WH FAN1_TACH

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Prepared by, date: Approved by, date: COOLING 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

COMPUTER UNIT CONTROL

=CM MODULE
+A3
MAIN COMPUTER
OPTION: =CM
PWR LED (GREEN)
232/485 SERIE CONVERTER +A31
=CM -J9H3 A K
SERIAL PORT A
+A39 2
-X1 -X2 -A1
RX-
TX+ 1 1 TRANSMIT OUT 1 4
HDD LED (YELLOW)
TX- 2 2 RECEIVE IN 2
3 3 DTR 3 A K
0V 4 4 0V 4 1
5 5 5
6 6 RTS 6 3
OPT. EXTERNAL PWR 7 7 7
RX+ 8 8 8
9 9 9
-LAN1
TX+
1 TX-
2 RX+
3 RX-
6

=CM
+X24
-USB1 2
AWG28 WH USB-BP1
2 AWG28 GN USB-BP1 3
3 AWG24 RD +5V 1
1 AWG24 BK GND 4
4

-USB2
AWG28 WH -USB-BP2 / /8.7
2 AWG28 GN -USB-BP2 / /8.7 PROCESS
3 AWG24 RD -USB +5V / /8.6 POWER SUPPLY
1 AWG24 BK -USB_GND / /8.7
4

-USB3

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1

We reserve all rights in this document and in the information contained therein.Reproduction, use or
2
3
4

-USB4
1
2
3
4

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MAIN COMPUTER Document no. Rev. Ind Page 23
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Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

ROBOT COMMUNICATION CARD

=CM
+A32

-X8 AWG24
Blue

1
2 OG -24V_Sig.ref. / /10.7
3 BU -RS485+ / /10.7
RS 485 4 WHBU -RS485- / /10.7 PANEL BOARD
5
6 WHBN -0V_Sig.ref. / /10.7
-X1
7
8

PCI BUS
AWG24

-A8
Green WHOG -TD+ / /17.2
3 OG -TD- / /17.2 FLEXPENDANT
ETH_FPU 6
4
5 WHGN -RD+ / /17.2
1 GN -RD- / /17.2
2
7
8

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Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

CONTROL
MODULE

ROBOT COMMUNICATION CARD

=CM
+A32
-A9
Red
TX+
1 TX-
2 RX+
3 RX- DRIVE MODULE
ETH_DRIVE 6 AXIS COMPUTER
4
5
7
8

=CM
+X23
-A7
Yellow 1
TX+ AWG26 BU
1 TX- AWG26 WHBU 2 SERVICE
2 RX+ AWG26 OG 3 PORT
ETH_SERVICE 3
4
5 RX- AWG26 WHOG 6
6
7
8

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We reserve all rights in this document and in the information contained therein.Reproduction, use or
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Next 26
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

PROFIBUS DP M/S
=CM
+A33 Customer
Connection

-X1
-X2
SHIELD
RXD/TXD-P 1
SLAVE CONTROL-P 3
PCI BUS GND 4
+5VDC 5
RXD/TXD-N 6
8

-X3
SHIELD
RXD/TXD-P 1
MASTER CONTROL-P 3
GND 4
OPTION & HARNESS TO CUSTOMER I/O

+5VDC 5
RXD/TXD-N 6
8

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 1 2 3 4 5 6 7 8

INTERBUS M/S (OPTICAL FIBRE) INTERBUS M/S (COPPER WIRE)

=CM A37.1 =CM A38.1 1)
-X4
+A37 +A38 24V
24V+
1) 0V
-X2
24V 0V
-Z1
24V+
-Z1
0V
REMOTE IN -X5
0V DO
1 DON
4 DI
-FO1
PCI BUS LW/BK 2 DIN
REMOTE IN BK (IN) 5
PCI BUS GNDISI
LW/OG 3
GY (OUT)

-FO2
LW/BK
REMOTE OUT REMOTE OUT -X1
BK (IN) DO
LW/OG 1 DON
GY (OUT) 6 DI
2 DIN
7 GRND
3 VCCISO
A37.2 5 RBST
9

-FO3
LW/BK
REMOTE
BK (IN)
LW/OG
GY (OUT)
A38.2

OPTION & HARNESS TO CUSTOMER I/O

REMOTE -X2
DO
OPTION & HARNESS TO CUSTOMER I/O

1 DON
6 DI
2 DIN
7 GNDIM
-X1
TXD 3 GRND
1 RXD 4 VCCIM
2 GND 5 VCC
4 RTS 8
5 CTS
6

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
RS232 -X3
TXD
1 RXD
2 GND
4 RTS
5 CTS
6

1) IT IS IMPORTANT THAT 24 DC EXT SUPPLY ALWAYS IS AVAILABLE

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

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 1 2 3 4 5 6 7 8

CONTROL
DEVICE NET ADAPTER
MODULE
=CM
+A35
-XS17
-J1 -A35.X1
P1 BK
1 1 3
BU
2 2 5
SC
3 3 1
WH OPTION
4 4 4
PCI BUS RD
5 5 2

-V- / /29.2

-CAN_L / /29.2

-DRAIN / /29.2

-CAN_H / /29.2

-V+ / /29.2

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 1 2 3 4 5 6 7 8

-I/O1
/28.5 / -V-
/28.5 / -CAN_L 1
/28.5 / -CAN_H 2
/28.5 / -V+ 3
/28.5 / -DRAIN 4 BK -V- / /32.1
5 BU -CAN_L / /32.1
WH -CAN_H / /32.1 Digital I/O unit
RD -V+ / /32.1
-I/O2
SC -DRAIN / /32.1
1
2 BK -V- / /35.1
3 BU -CAN_L / /35.1
4 WH -CAN_H / /35.1 Relay I/O unit
5 RD -V+ / /35.1
SC -DRAIN / /35.1
-I/O3
BK -V- / /38.1
1 BU -CAN_L / /38.1
2 WH -CAN_H / /38.1 Analogue I/O unit
3 RD -V+ / /38.1
4 SC -DRAIN / /38.1
5
BK -V- / /39.1 OPTION: HARNESS
BU -CAN_L / /39.1 TO CUSTOMER I/O
-I/O4
WH -CAN_H / /39.1 Remote I/O unit
1 RD -V+ / /39.1
2 SC -DRAIN / /39.1
3
4 BK -V- / /40.2
5 BU -CAN_L / /40.2
WH -CAN_H / /40.2 Interbus slave
RD -V+ / /40.2
SC -DRAIN / /40.2

BK -V- / /41.1
BU -CAN_L / /41.1
-A35.X2
/9.2 / -0V devicenet WH -CAN_H / /41.1 Profibus DP slave
1 RD -V+ / /41.1
SC -DRAIN / /41.1
2

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
120 OHM

We reserve all rights in this document and in the information contained therein.Reproduction, use or
BK -V- / /42.1
3 BU -CAN_L / /42.1
WH -CAN_H / /42.1 Encoder unit
4 RD -V+ / /42.1
/9.2 / -+24V devicenet SC -DRAIN / /42.1
5

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 1 2 3 4 5 6 7 8

DUAL RS232 CARD

=CM
+A34

-X1
1 CONSOLE_RXD
2 CONSOLE_TXD
3 CONSOLE_DTR
MC CONSOLE 4 0V
RS232 5 CONSOLE_DSR
6 CONSOLE_RTS-N
7 CONSOLE_CTS-N
8
X5 9

-X2
1 COM1_RXD
PCI BUS 2 COM1_TXD
3 COM1_DTR
COM1 4 0V
RS232 5 COM1_DSR
6 COM1_RTS-N
7 COM1_CTS-N
8
9

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 1 2 3 4 5 6 7 8

ETHERNET CARD
=CM
+A36

-A1
TX+
1 TX-
2 RX+
3 DRIVE MODULE 2 (OPTION)
4
5 RX-
X1 6
7
8

-A2
TX+
1 TX-
PCI BUS 2 RX+
3 DRIVE MODULE 3 (OPTION)
4
5 RX-
6
7
8

-A3
TX+
1 TX-
2 RX+
3 DRIVE MODULE 4 (OPTION)
4
5 RX-
6
7

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
8

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 1 2 3 4 5 6 7 8

TO NEXT
I/O UNIT

2)
120 ohm
3) 2 1

/9.3 / -+24V devicenet

/9.3 / -0V devicenet
DIGITAL PART OF COMBI I/O AND DIGITAL I/O UNIT
I/Ox XTXX.X3

K A
-X3
INPUT CH.1
1 2
2 3
A
3 4
-X5
/29.5 / -V- K 4 5
/29.5 / -CAN_L 1 5 6
/29.5 / -CAN_H 2 6 7
47nF
/29.5 / -V+ 4 7 8
5 1 2 8 0V
/29.5 / -DRAIN 9
0V 3 10
OR PREVIOUS NA0 6
0V
I/O UNIT NA1 7
1) NA2 8
NA3 9
NA4 10 XTXX.X4
NA5 11
K A
-X4
12 INPUT CH.9
1 10
2 11
3 12
A
4 13
K 5 14
6 15
47nF
1) JUMPERS PLACED ACCORDING TO 7 16
THE ACTUAL NODE ADDRESS. 1 2 8 0V
9
10
2) RESISTANS 120 OHM SHALL ALWAYS
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
3) CONNECTED IN THE LAST CONNECTOR IN THE
CAN-BUS CIRCUIT.

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Next 33
Prepared by, date: Approved by, date: DIGITAL I/O UNIT 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

DIGITAL I/O UNIT

I/Ox

OUTPUT CH 1-8

XTXX.X1
A -X1
<1 OUTPUT CH.1
K 1 2
1 2 3
3 4
4 5
2
5 6
A
6 7
47nF
K 7 8
2 1 8 0V
0V
9 24V DC
10

OUTPUT CH 9-16
XTXX.X2

A -X2
<1 OUTPUT CH.9
K 1 10
1 2 11
3 12
4 13
2
5 14
A
6 15
47nF
K 7 16
2 1 8 0V
9 24V DC
10

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
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 1 2 3 4 5 6 7 8

COMBI I/O UNIT

I/Ox

OUTPUT CH 1-8

XTXX.X1
A -X1
<1 OUTPUT CH.1
K 1 2
1 2 3
3 4
4 5
2
5 6
A
6 7
47nF
K 7 8
2 1 8 0V
0V
9 24V DC
10

OUTPUT CH 9-16
XTXX.X2

A -X2
<1 OUTPUT CH.9
K 1 10
1 2 11
3 12
4 13
2
5 14
A
6 15
47nF
K 7 16
2 1 8 0V
9 24V DC
10

-X6
INPUT CH.1
CPU INPUT CH.2 1
2
K K

A A
0V
3

DAC
OUTPUT CH.1

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
5

We reserve all rights in this document and in the information contained therein.Reproduction, use or
REF 0VA
4
OUTPUT CH.2
6

+15V
DC
0VA
DC
-15V

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Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

TO NEXT
I/O UNIT

2)
120 ohm
2 1

3)
RELAY I/O UNIT
/9.3 / -+24V devicenet I/Ox
/9.3 / -0V devicenet XTXX.X3

K A
-X3
INPUT CH.1
1 2
2 3
A
3 4
-X5
/29.5 / -V- K 4 5
/29.5 / -CAN_L 1 5 6
/29.5 / -CAN_H 2 6 7
47nF
/29.5 / -V+ 4 7 8
5 1 2 8 0V
/29.5 / -DRAIN 9
0V 3
OR PREVIOUS NA0 6
0V
I/O UNIT NA1 7
1) NA2 8
NA3 9
NA4 10 XTXX.X4
NA5 11
K A
-X4
12 INPUT CH.9
1 10
2 11
3 12
A
4 13
K 5 14
6 15
47nF
1) JUMPERS PLACED ACCORDING TO 7 16
THE ACTUAL NODE ADDRESS. 1 2 8 0V
9

2) RESISTANS 120 OHM SHALL ALWAYS

BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
3) CONNECTED IN THE LAST CONNECTOR IN THE
CAN-BUS CIRCUIT.

Latest revision: Lab/Office: Status: Plant: = CM

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 1 2 3 4 5 6 7 8

RELAY I/O UNIT

XTXX.X1

-X1
OUT CH.1A
1

OUT CH.1B
2

OUT CH.2A
3

OUT CH.2B
4

OUT CH.3A
5

OUT CH.3B
6

OUT CH.4A
7

OUT CH.4B
8

OUT CH.5A
9

OUT CH.5B
10

OUT CH.6A
11

OUT CH.6B
12

OUT CH.7A
13

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
OUT CH.7B
14

OUT CH.8A
15

OUT CH.8B
16

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 1 2 3 4 5 6 7 8

RELAY I/O UNIT

XTXX.X2

-X2
OUT CH.9A
1

OUT CH.9B
2

OUT CH.10A
3

OUT CH.10B
4

OUT CH.11A
5

OUT CH.11B
6

OUT CH.12A
7

OUT CH.12B
8

OUT CH.13A
9

OUT CH.13B
10

OUT CH.14A
11

OUT CH.14B
12

OUT CH.15A
13

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
OUT CH.15B
14

OUT CH.16A
15

OUT CH.16B
16

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 1 2 3 4 5 6 7 8

TO NEXT
I/O UNIT

2)
120 ohm
2 1 ANALOGUE I/O UNIT
I/Ox

3)
-X7
ANOUT_1
/9.3 / -+24V devicenet 1 ANOUT_2
/9.3 / -0V devicenet 2 ANOUT_3
ADC MUX 3 ANOUT_4
4 0V
19 0V
0V 20 0V
21 0V
-X5
/29.5 / -V- 22
/29.5 / -CAN_L 1
/29.5 / -CAN_H 2
/29.5 / -V+ 4
5
/29.5 / -DRAIN
0V 3 REF
DAC
OR PREVIOUS NA0 6
-X8
I/O UNIT NA1 7 ANIN_1
1) NA2 8 1 ANIN_2
NA3 9 2 ANIN_3
NA4 10 3 ANIN_4
NA5 11 4
12 24V
5
6
7
8
9
0V 10
1) JUMPERS PLACED ACCORDING TO 11

THE ACTUAL NODE ADDRESS. 0V

12 0V
13 0V
2) RESISTANS 120 OHM SHALL ALWAYS
14 0V
BE CONNECTED IN THE FIRST AND THE 15
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
3) CONNECTED IN THE LAST CONNECTOR IN THE
CAN-BUS CIRCUIT.

Latest revision: Lab/Office: Status: Plant: = CM

Approved Location: + ORT
EPLAN Sublocation: +
ANALOGUE I/O UNIT Document no. Rev. Ind Page 38
Next 39
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

TO NEXT
I/O UNIT

2)
120 ohm
2 1

3)

/9.3 / -+24V devicenet

/9.4 / -0V devicenet REMOTE I/O UNIT
I/Ox

-X5
/29.5 / -V-
/29.5 / -CAN_L 1 NAC
/29.5 / -CAN_H 2
-X8
/29.5 / -V+ 4 LINE 1 (BLUE)
5 1 REMOTE I/O IN
/29.5 / -DRAIN
0V 3 LINE 2 (CLEAR)
OR PREVIOUS NA0 6 1 2

I/O UNIT NA1 7

-X9
1) NA2 8 (BLUE)
NA3 9 1 REMOTE I/O OUT
NA4 10
NA5 11 (CLEAR)
12 2

3
-X8
3

1
1
1) JUMPERS PLACED ACCORDING TO
THE ACTUAL NODE ADDRESS. 2
2

2) RESISTANS 120 OHM SHALL ALWAYS

BE CONNECTED IN THE FIRST AND THE 4
LAST CONNECTOR IN THE CAN-BUS CIRCUIT. -X9
4

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
3) CONNECTED IN THE LAST CONNECTOR IN THE
CAN-BUS CIRCUIT.

Latest revision: Lab/Office: Status: Plant: = CM

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 1 2 3 4 5 6 7 8

TO NEXT
I/O UNIT

2)
120 ohm
2 1

3)

/9.4 / -+24V devicenet INTERBUS SLAVE

/9.4 / -0V devicenet I/Ox

-X5
/29.5 / -V-
-X21
/29.5 / -CAN_L 1 TPDO2
/29.5 / -CAN_H 2 1 TPDI2
/29.5 / -V+ 4 2 GND
5 3 +5VDC IB-S OUT
/29.5 / -DRAIN 5 TPDO2-N
0V 3 6 TPDI2-N
OR PREVIOUS NA0 6 7 RBST
I/O UNIT NA1 7 9
1) NA2 8
NA3 9
NA4 10
NA5 11
12

-X20
TPDO1
1 TPDI1
2 GND IB-S IN
3 TPDO1-N
6 TPDI1-N
-X3
GND 7
4) 24V DC EXT. SUPPLY 1
+24VDC 3
5
1) JUMPERS PLACED ACCORDING TO
THE ACTUAL NODE ADDRESS.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
2) RESISTANS 120 OHM SHALL ALWAYS

We reserve all rights in this document and in the information contained therein.Reproduction, use or
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

3) CONNECTED IN THE LAST CONNECTOR IN THE

CAN-BUS CIRCUIT.

4) IT IS IMPORTANT THAT 24V DC EXT SUPPLY

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

Latest revision: Lab/Office: Status: Plant: = CM

Approved Location: + ORT
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INTERBUS SLAVE Document no. Rev. Ind Page 40
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 1 2 3 4 5 6 7 8

TO NEXT
I/O UNIT

2)
120 ohm
2 1

3) PROFIBUS DP SLAVE
I/Ox
/9.4 / -+24V devicenet
/9.4 / -0V devicenet Customer
Connection

-X5
/29.5 / -V-
-X20
/29.5 / -CAN_L 1 SHIELD
/29.5 / -CAN_H 2 1
/29.5 / -V+ 4 RXD/TXD-P
5 3 CONTROL-P
/29.5 / -DRAIN 4 GND
0V 3 5 +5VDC
OR PREVIOUS NA0 6 6 RXD/TXD-N
I/O UNIT NA1 7 8
1) NA2 8
NA3 9
NA4 10
NA5 11
12

-X3
0V DC
External supply GND 1
+24VDC 3
5

1) JUMPERS PLACED ACCORDING TO

THE ACTUAL NODE ADDRESS.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
2) RESISTANS 120 OHM SHALL ALWAYS
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

3) CONNECTED IN THE LAST CONNECTOR IN THE

CAN-BUS CIRCUIT.

Latest revision: Lab/Office: Status: Plant: = CM

Approved Location: + ORT
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PROFIBUS DP SLAVE Document no. Rev. Ind Page 41
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 1 2 3 4 5 6 7 8

TO NEXT
I/O UNIT

2)
120 ohm
2 1

3)
ENCODER UNIT
/9.4 / -+24V devicenet I/Ox Encoder
/9.4 / -0V devicenet Connection

-X20
24 VDC
1
-X5
/29.5 / -V- 0V
/29.5 / -CAN_L 1 2
/29.5 / -CAN_H 2 ENC +24V
/29.5 / -V+ 4 3
5 ENC 0V
/29.5 / -DRAIN 4 Encoder
0V 3 2 1 ENC_A
OR PREVIOUS NA0 6 5
NA1 7 A ENC_B
I/O UNIT
1) NA2 8 6
K
NA3 9 +24V
NA4 10 7
NA5 11 0V Synch switch
12 2 1 8
DIGIN
A 9

2 1
1) JUMPERS PLACED ACCORDING TO
A
THE ACTUAL NODE ADDRESS.
K
2) RESISTANS 120 OHM SHALL ALWAYS
BE CONNECTED IN THE FIRST AND THE
LAST CONNECTOR IN THE CAN-BUS CIRCUIT.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
3) CONNECTED IN THE LAST CONNECTOR IN THE
CAN-BUS CIRCUIT.

Latest revision: Lab/Office: Status: Plant: = CM

Approved Location: + ORT
EPLAN Sublocation: +
ENCODER UNIT Document no. Rev. Ind Page 42
Next
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 42
 1 2 3 4 5 6 7 8

EPLAN

The information in this document is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

In no event shall ABB be liable for incidental or consequential damages arising from use of this document
or of the software and hardware described in this document.

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

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

© Copyright 2004 ABB All right reserved.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
ABB Automation Technologies AB

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Robotics
SE-721 68 Västerås
Sweden

Latest revision: Lab/Office: Status: Plant: = DOKUMENTE

Approved Location: + DKB
EPLAN Sublocation: +
Title page Document no. Rev. Ind Page 1
Next 2
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 18
 1 2 3 4 5 6 7 8

EPLAN

Phone :

Customer :
Robot serial number(s) :
Drawing number : 3HAC020538-002_Drive
Drawing version :
Manufacture : 2004-09-28
Type :
Type of installation :
Control cabinet :
Mains voltage :
Supply :
Control voltage :
Year of construction :

Project start : 2004-02-04

Project manager :
Last revision :

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Designed by : jsundin1

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Designed date : 2004-09-28
Number of pages : 18
:

Latest revision: Lab/Office: Status: Plant: = DOKUMENTE

Approved Location: + DKB
EPLAN Sublocation: +
Title page Document no. Rev. Ind Page 2
Next 3
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 18
 1 2 3 4 5 6 7 8

Table of contents DIN_INV_30_1

Plant Location Page Page description Page supplementary field Date Editor
DOKUMENTEDKB 1 Title page Approved 2004-09-13 jsundin1
DOKUMENTEDKB 2 Title page Approved 2004-09-13 jsundin1
DOKUMENTEINV 3 Table of contents: (1 - 18) Approved 2004-09-23 jsundin1
DM ORT 4 VIEW OF DRIVE MODULE Approved 2004-09-22 jsundin1
DM ORT 5 VIEW OF DRIVE MODULE Approved 2004-09-22 jsundin1
DM ORT 6 MAINS CONNECTION Approved 2004-09-22 jsundin1
DM ORT 7 TRANSFORMER UNIT Approved 2004-09-23 jsundin1
DM ORT 8 POWER SUPPLY Approved 2004-09-22 jsundin1
DM ORT 9 CONTACTOR BOARD Approved 2004-09-22 jsundin1
DM ORT 10 POWER UNITSERVO DISCONNECTOR Approved 2004-09-22 jsundin1
DM ORT 11 AXIS COMPUTER UNIT Approved 2004-09-22 jsundin1
DM ORT 12 AXIS COMPUTER UNIT Approved 2004-09-22 jsundin1
DM ORT 13 VIEW OF DRIVE MODULE Approved 2004-09-22 jsundin1
DM ORT 14 RECTIFIER AND BLEEDER Approved 2004-09-22 jsundin1
DM ORT 15 FAN UNIT Approved 2004-09-22 jsundin1
DM ORT 16 ADDITIONAL AXIS 1-3, DRIVE UNIT NO 7 Approved 2004-09-22 jsundin1
DM ORT 17 ADDITIONAL AXIS 1-3, DRIVE UNIT NO 8 Approved 2004-09-22 jsundin1
DM ORT 18 ADDITIONAL AXIS 1-3, DRIVE UNIT NO 9 Approved 2004-09-22 jsundin1

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = DOKUMENTE
Approved Location: + INV
EPLAN Sublocation: +
Table of contents: (1 - 18) Document no. Rev. Ind Page 3
Next 4
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 18
 1 2 3 4 5 6 7 8

A41.1.4 A41.1.3
A41.1 A41.2

K43 A41.3

Z1 G1
K44
K42 Q1

H1

A43
F1
P1
K41 (opt duty time counter)

F2
XP0

XS25

XS41
A42
XS1
XS2
XS7

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = DM
Approved Location: + ORT
EPLAN Sublocation: +
VIEW OF DRIVE MODULE Document no. Rev. Ind Page 4
Next 5
Prepared by, date: Approved by, date: 02 Total 18
 1 2 3 4 5 6 7 8

A42 Axis computer unit

A43 Contactor unit

X7 X5 X9 X11 X6 X4
X8

X9
X22
X2

X21 X3
X8

X23
X24 X11
X5
X1 X10 X12

X4

X10 X6
X1

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = DM
Approved Location: + ORT
EPLAN Sublocation: +
VIEW OF DRIVE MODULE Document no. Rev. Ind Page 5
Next 6
Prepared by, date: Approved by, date: 02 Total 18
 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
Latest revision:
1

Prepared by, date:

2

Approved by, date:

3

-Q1
-XP0

/7.3 / -L1 -110 AWG10 BK -101 AWG10 BK

2
1
1

/7.3 / -L2 -111 AWG10 BK -102 AWG10 BK

4
3
2

-112 AWG10 BK -103 AWG10 BK

4

/7.4 / -L3
6
5
3

EPLAN
TRANSFORMER UNIT
AWG10 GNYE
4

Lab/Office:
-F6

-Z1
5

107

2
1
2
1

108

4
3
4
3

109

6
5
6
5

MAINS CONNECTION
OPTION:

OPTION:
6

CIRCUIT BRAKER

MAINS LINE FILTER

Status:
7

Document no.
Approved
Plant:
Location:
Sublocation: +
= DM
8

3HAC020538-002 02
+ ORT

Next 7
Rev. Ind Page 6

Total 18
 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
Latest revision:
1

Prepared by, date:

+T1
=DM

200V
220V
400V
-X2
TRANSFORMER UNIT

/8.4 / -230V AC1 1 230V

440V
2

-X1

/8.4 / -230V AC2 2 230V 480V

500V
Approved by, date:

525V
600V
200V
/10.7 / -L1 -119 AWG10 BK
220V
3

/10.7 / -L2 -120 AWG10 BK

400V
-X10

/10.7 / -L3 -121 AWG10 BK -113 AWG10 BK -110 BK -L1 / /6.4

440V
A1

-114 AWG10 BK -111 BK -L2 / /6.4

480V
A2

500V -115 AWG10 BK -112 BK -L3 / /6.4

B1

525V
MAINS CONNECTION

600V
B2

=DM
+L1
4

200V

EPLAN
AWG10 GNYE

220V
400V

-X2
-X1

-L1
440V

1
1

F2
F1
480V

Lab/Office:
2
2
AWG10 GNYE

F4
F3
500V
525V

3
3

F6
F5
600V
5

ONLY FOR IRB 6600-7600

TRANSFORMER UNIT
+T2
=DM
6

IRB7600 480V
TRANSFORMER UNIT

T2 USED FOR:
-X2
-X1
IN

IRB6600 400-480V
230V

Status:
400V

DIRECT POWER SUPPLY

7

440V

Document no.
Approved
480V
113
114

Plant:
Location:
115

Sublocation: +
= DM
8

3HAC020538-002 02
+ ORT

Next 8
Rev. Ind Page 7

Total 18
 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
Latest revision:
1

Prepared by, date:

+G1
=DM

-X2

UNIT

/11.2 / -24V DRIVE BK

1

/11.2 / -0V DRIVE BN

4

AXIS COMP.
DRIVE POWER SUPPLY
2

/15.2 / -24V DRIVE RD

2

/15.2 / -0V DRIVE OG

5

DRIVE UNIT

Approved by, date:

MAIN SERVO

/9.2 / -24V DRIVE -463 BU

3

UNIT

/9.2 / -0V DRIVE -464 BU

6

CONTACTOR
3

-X3

/9.2 / -24V BRAKE -465 AWG16

1

/9.2 / -24V BRAKE -466 AWG16 BU

2

UNIT
/9.2 / -+24V COOL -469 AWG16
3
-F2

/9.2 / -0V BRAKE -467 AWG16

CONTACTOR
5

/9.2 / -0V BRAKE -468 AWG16 BU

-X1

6
3

-470 AWG16
4

/9.2 / -0V COOL

7

-152 AWG16 BK 1 -230V AC1 / /7.2

1

EPLAN
2

/15.2 / -+24V COOL -461 AWG16 BU

4

-153 BK -156 BK 2 -230V AC2 / /7.2

5
14
11
3

/15.2 / -0V COOL -462 AWG16 BU

8

DRIVE UNIT
MAIN SERVO
-X4
/11.2 / -+5V BK

Lab/Office:
1

UNIT
/11.2 / -ACOK BN 2
/11.2 / -BRAKEOK RD

3
5

AXIS COMP.
/11.2 / -TEMPOK OG

POWER SUPPLY
-K41

A2
A1
-155
-154
6

-141
-140
AWG16 BK
AWG16 BK

AWG20 BU
AWG20 BU
2
1

2
1
GND
-XS25

-K41.X1

Status:
7

Document no.
Approved
GND

0V
230V AC2
230V AC1

Plant:
AC_ON

Location:
Sublocation: +
= DM
8

X20

3HAC020538-002 02
+ ORT
A21.X7
MODULE
MODULE

CONTROL
CONTROL

Next 9
Rev. Ind Page 8
PANEL BOARD

Total 18
 1 2 3 4 5 6 7 8

CONTACTOR UNIT
=DM
DRIVE +A43
-464 BU
-X6 -X5
POWER /8.3 / -0V DRIVE PTC1
1 1
SUPPLY
/8.3 / -24V DRIVE -463 BU 0V BRAKE
2 2
PTC1 ret
3
-X1
RUN CH1 0V BRAKE
CONTROL RUN CH1 RET 1 4

MODULE RUN CH2 2

RUN CH2 RET 3
A21.X7 -X10
4 0V COOL
1
+24V COOL
-X22
LIMIT LIM2 ch1 2
24VDrive
SWITCH 2 LIM2 ch2 1 FAN1
0VDrive
3 3
EXTERNAL
LIM2 ch2 ret FAN1 ret
AXIS
LIM2 ch1 ret 4 4
2

24VDrive -X11
0V COOL
-X23
1
LIMIT 1 +24V COOL
OVERRIDE 3 2
FAN2
4 3
2 FAN2 ret
4
OPTION:
DUTY TIME COUNTER
-X21 -P1
LIMIT LIM1 ch1
SWITCH 1 LIM1 ch2 1 0VDrive
-X12 -491 AWG20 BU +24V
3 +
CONTROL
LIM1 ch2 ret LIM2 1
CABLE
LIM1 ch1 ret 4 LIM1
2
h
-492 AWG20 BU 0V -
2
-X1
CONTROL ENABLE2_1
MODULE ENABLE2_1Ret 5 INTERLOCKING
SPEED 6
A21.X7
0V 7
8

AWG24 K2
-X4

RUN_CH2
RUN_CH1
24V COOL

AXIS /11.2 / -RS485+ BU K1

BRAKE CTRL

COMPUTER /11.2 / -RS485- WHBU 4 24V COOL

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
PAN_CH1

OG 5

We reserve all rights in this document and in the information contained therein.Reproduction, use or
/11.2 / -0V ENABLE2
/11.2 / -ENABLE2 WHOG 7
8
24V COOL

-X7
PAN_CH2

/8.3 / -24V BRAKE -466 AWG16 BU

DRIVE /8.4 / -0V COOL -470 AWG16 BU 1

POWER /8.4 / -+24V COOL -469 AWG16 BU 2

/8.3 / -24V BRAKE -465 AWG16 BU 3
SUPPLY
SELF1
SELF2

/8.4 / -0V BRAKE -467 AWG16 BU 4

LOCK1A
LOCK2B
0V COOL
0V COOL

RUN_CH1
RUN_CH2

-468 AWG16 BU 5
BRAKE

/8.4 / -0V BRAKE

0V COOL

6
CONTINUATION NEXT PAGE

Latest revision: Lab/Office: Status: Plant: = DM

Approved Location: + ORT
EPLAN Sublocation: +
CONTACTOR BOARD Document no. Rev. Ind Page 9
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Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 18
 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
Latest revision:
1

Prepared by, date:

+A43
=DM

-X8

-K42

-471 AWG20 BU 0V COOL

2

-472 AWG20 BU RUN CH1

1

A2
A1
CONTACTOR UNIT

-K44

-473 AWG20 BU 0V COOL

2

-474 AWG20 BU BRAKE

5

A2
A1

Approved by, date:

-K43

-475 AWG20 BU 0V COOL

4

-476 AWG20 BU RUN CH2

3

A2
A1
-X3

-451 AWG20 BU 24V

1

-452 AWG20 BU BRAKE_FB

3

1
2
6

-479 AWG20 BU 0V
5

-493 AWG20 BU -480 AWG20 BU SELF1

4

44
43

-481 AWG20 BU 24V

-H1
10

-494 AWG20 BU -482 AWG20 BU

STATUS DIOD

SELF2
9

44
43

-483 AWG20 BU LOCK1B

3

22
21

-484 AWG20 BU LOCK1A

2
4

-485 AWG20 BU LOCK2A

7

EPLAN
22
21

-486 AWG20 BU LOCK2B

8

EXT MON 1A
EXTCONT
EXT MON 1B &
-X24

34
33

EXT MON 2A

Lab/Office:
3

CUSTOMER
EXT MON 2B 0V

CONNECTION
4

34
33
5
5

24V DRIVE
6

PTC2
1

POWER UNIT
PTC2 0V
2

-X40
EXT. LAMP -445 AWG16 BU

1
-X9

BRAKE REL. -447 AWG16 BU -490 BU -489 BU -487 AWG16 BU 24V BRAKE

4
3

2
1

14
13
13
14

BRAKE REL. -448 AWG16 BU

SERVO DISCONNECTOR
3
6

BRAKE PB -446 AWG16 BU -488 AWG16 BU 24V BRAKE

4
2

22
21

AND OPTION:
EXT. BRAKE REL. -449 AWG16 BU BRAKE PB

6
5

EXTERNAL AXIS
5
3

CONTROL CABLE
EXT. BRAKE PB -450 AWG16 BU

6
-F1

Status:
/14.4 / -L12 -128 AWG10 BK -122 BK -119 AWG10 BK -L1 / /7.3

2
1
2
1
I>
2
1
7

Document no.
AWG10 BK BK AWG10 BK

Approved
/14.5 / -L22 -129 -123 -120 -L2 / /7.3

4
3
4
3
I>
4
3

RECTIFIER
/14.5 / -L32 -130 AWG10 BK -124 BK -121 AWG10 BK -L3 / /7.3

6
5
6
5
I>
6
5

Plant:
Location:
Sublocation: +
= DM
8

3HAC020538-002 02
+ ORT

Total 18
Next 11
Rev. Ind Page 10
 1 2 3 4 5 6 7 8

AXIS COMPUTER UNIT

=DM
+A42 MAIN SERVO DRIVE UNIT
=DM
+A41.1
-X1
DRIVE POWER /8.2 / -0V DRIVE BN
SUPPLY 1
/8.2 / -24V DRIVE BK
2
-X11 AWG26
BK
-X1
+FRAME RECEIVER
-X10
/8.5 / -+5V BK 1 1
DRIVE POWER 1 BN -FRAME RECEIVER
SUPPLY /8.5 / -ACOK BN 2 2
2 BK +CLK RECEIVER
/8.5 / -BRAKEOK RD 6 6
3 RD -CLK RECEIVER
/8.5 / -TEMPOK OG 7 7
4 BK +DATA RECEIVER
11 11
OG -DATA RECEIVER
12 12
BK +FRAME TRANSMITTER
-X2
TX+ 3 3
CONTROL 1 YE -FRAME TRANSMITTER
MODULE TX- 4 4
2 BK +CLK TRANSMITTER
A32.A9
RX+ 8 8
RCC GN
3 -CLK TRANSMITTER
RX- 9 9
6 BK +DATA TRANSMITTER
13 13
AWG24 BU -DATA TRANSMITTER
BU
-X6
/9.2 / -RS485+ 14 14
CONTACTOR 4 BK GND
UNIT /9.2 / -RS485- WHBU 5 5
5
/9.2 / -0V ENABLE2 OG
7
/9.2 / -ENABLE2 WHOG
8

-X9
RXD
2

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
TXD

We reserve all rights in this document and in the information contained therein.Reproduction, use or
3
0V
5

Latest revision: Lab/Office: Status: Plant: = DM

Approved Location: + ORT
EPLAN Sublocation: +
AXIS COMPUTER UNIT Document no. Rev. Ind Page 11
Next 12
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 18
 1 2 3 4 5 6 7 8

AXIS COMPUTER UNIT DRIVE

=DM MODULE
+A42
-X4 -XS2
MRCO1
1 A
MRCO1_N
2 B
MRCI1
4 C
MRCI1_N
5 D CONTROL
-X8
GND_O2 0V SIGNAL
1 6 E
24V_EXT2 24V_SMB1
2 7 F
0V
3 3 G
IN 2 0V
4 9 J

5
IN 1
6
-X5 -XS41
GND_01 MRCO2
PROCESS I/O 7 1 A
24V_EXT1 MRCO2_N
8 2 B
OUT 2 MRCI2
9 4 C
MRCI2_N EXT. AXIS
10 5 D SIGNAL
GND_I2 0V
11 6 E
24V_SMB2
12 7 F
GND_I1 0V
13 3 G
0V
14 9 J
OUT 1
15

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 1 2 3 4 5 6 7 8

3 UNITS FOR IRB140, IRB1400, IRB2400, IRB340 6 UNITS FOR IRB4400, IRB940, IRB6600, IRB7600

A41.1.4
A41.1 SINGLE SERVO DRIVE UNIT
MAIN SERVO DRIVE UNIT OPTION: EXT AXIS 8
A41.1.3
DC-BUSBAR SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 7
A41.2
RECTIFIER A41.2
RECTIFIER

A41.1.3 DC-BUSBAR
SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 7
A41.1

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A41.1.4 MIAN SERVO DRIVE UNIT
SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 8
DC-BUSBAR
A41.1.5
SINGLE SERVO DRIVE UNIT
OPTION: EXT AXIS 9

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 1 2 3 4 5 6 7 8

CONTACTOR UNIT

-L12 / /10.7
-L22 / /10.7
-L32 / /10.7

AWG10 BK
AWG10 BK
AWG10 BK

-128
-129
-130
AWG10 GNYE
MAIN SERVO DRIVE UNIT
=DM RECTIFIER
+A41.1 =DM -X32 1 2 3 4 BLEEDER
+A41.2
-X33 -132 AWG12 BK
1
AWG26 1
-X2 BK
-X30
Spare -R1.1
Spare 1 BN 1
2
+24V 2 BK 2
0V 6 RD 6 -133 AWG12
DATA_TO_DRIVE 7 BK 7 2
DATA_TO_DRIVE_N 11 OG 11
ENABLE 12 BK 12
ENABLE_N 3 YE 3
CLK 4 BK 4
CLK_N 8 GN 8
DATA_TO_RECT 9 BK 9
CAPACITOR UNIT
DATA_TO_RECT_N 13 BU 13 =DM
0V 14 BK 14 +A41.3
VT
-X31 AWG20 BU
-X34
+5V 5 5 -69
10 10 1 1
-70 AWG20 BU
2 2
-71 AWG20 BU
3 3
-72 AWG20 BU
4 4

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DC-BUSBAR

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 1 2 3 4 5 6 7 8

MAIN SERVO DRIVE UNIT

=DM
+A41.1

-X3
DRIVE POWER /8.2 / -0V DRIVE OG
SUPPLY 1
/8.2 / -24V DRIVE RD FAN UNIT
2 =DM
+E1

-X5 -X5 -X1

+24V BK -354
+24V 1 1 VT 8 -350
-461 AWG16 BU
-X4 -X4
DRIVE POWER /8.4 / -+24V COOL 8 8 1 1 1 1 1
1 1 -E41 -E42 -E43 -E44
+
+
+
+

SUPPLY
/8.4 / -0V COOL -462 AWG16 BU
2 2 T1 OG -352 2 2 2 2
4 4 3
M M M M
- - - -
3 3 3 3
0V BU -351
0V 7 7 BN 2 -355
2 2 7
T2 YE -353
T3 5 5 RD 4 -356
T4 3 3 GN 5 -357
6 6 6

OPTION:

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52 deg.

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FAN UNIT Document no. Rev. Ind Page 15
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 1 2 3 4 5 6 7 8

MAIN SERVO DRIVE UNIT ADDITIONAL AXIS 1-3, DRIVE UNIT NO 7 SINGLE SERVO DRIVE UNIT
=DM =DM
+A41.1 +A41.1.3

-X7 -X20
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
16 16
17 17
19 19
20 20
21 21
22 22
15 15
23 23
18 18
24 24
25 25
26 26

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DC-BUSBAR

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 1 2 3 4 5 6 7 8

ADDITIONAL AXIS 1-3, DRIVE UNIT NO 8

MAIN SERVO DRIVE UNIT SIGNLE SERVO DRIVE UNIT
=DM =DM
+A41.1 +A41.1.4

-X8 -X20
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
16 16
17 17
19 19
20 20
21 21
22 22
15 15
23 23
18 18
24 24
25 25
26 26

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DC-BUSBAR

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 1 2 3 4 5 6 7 8

ADDITIONAL AXIS 1-3, DRIVE UNIT NO 9

MAIN SERVO DRIVE UNIT SINGLE SERVO DRIVE UNIT
=DM =DM
+A41.1 +A41.1.5

-X9 -X20
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
16 16
17 17
19 19
20 20
21 21
22 22
15 15
23 23
18 18
24 24
25 25
26 26

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DC-BUSBAR

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 1 2 3 4 5 6 7 8

EPLAN

The information in this document is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

In no event shall ABB be liable for incidental or consequential damages arising from use of this document
or of the software and hardware described in this document.

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

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

© Copyright 2004 ABB All right reserved.

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ABB Automation Technologies AB

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Robotics
SE-721 68 Västerås
Sweden

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 1 2 3 4 5 6 7 8

EPLAN

Phone :

Customer :
Robot serial number(s) :
Drawing number : 3HAC020538-002_Cables for 6600-7600
Drawing version :
Manufacture : 2004-09-23
Type :
Type of installation :
Control cabinet :
Mains voltage :
Supply :
Control voltage :
Year of construction :

Project start : 2004-02-16

Project manager :
Last revision :

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Designed by : jsundin1

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Designed date : 2004-09-23
Number of pages : 15
:

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 1 2 3 4 5 6 7 8

Table of contents DIN_INV_30_1

Plant Location Page Page description Page supplementary field Date Editor
DOKUMENTEDKB 1 Title page Approved 2004-09-09 jsundin1
DOKUMENTEDKB 2 Title page Approved 2004-09-09 jsundin1
DOKUMENTEINV 3 Table of contents: (1 - 15) Approved 2004-09-23 jsundin1
DM ORT 4 SERVO DRIVE SYSTEMIRB 6600-7600 Approved 2004-09-23 jsundin1
DM ORT 5 CONTROL CABLEIRB 6600-7600 Approved 2004-09-23 jsundin1
CM ORT 6 POSITION SWITCH 1IRB 6600-7600 Approved 2004-09-23 jsundin1
CM ORT 7 POSITON SWITCH 2/3IRB 6600-7600 Approved 2004-09-23 jsundin1
DM ORT 8 POSITION SWITCH 2/3 AND COOLING AXIS 1,2 Approved 2004-09-23 jsundin1
DM ORT 9 COOLINNG AXIS 1,2 Approved 2004-09-23 jsundin1
CM ORT 10 CUSTOMER POWER/SIGNALSIRB 6600-7600 Approved 2004-09-23 jsundin1
CM ORT 11 CUSTOMER POWER/SIGNALS/DeviceNetIRB 6600 Approved 2004-09-23 jsundin1
CM ORT 12 CUSTOMER POWER/SIGNALS/IBSIRB 6600-7600 Approved 2004-09-23 jsundin1
CM ORT 13 CUSTOMER POWER/SIGNALS/PROFIBUSIRB 6600- Approved 2004-09-23 jsundin1
DM ORT 14 EXTERNAL AXIS no 7 Approved 2004-09-23 jsundin1
DM ORT 15 EXTERNAL AXIS no 8 Approved 2004-09-23 jsundin1

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 We reserve all rights in this document and in the information contained therein.Reproduction, use or
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=DM
+A41.1

34
Latest revision:
1

Prepared by, date:

-R1.MP
-XS/XP1
-X11

GNRD -400 AWG12 BK

1

17
17

OGGN -401 AWG12 BK

2

24
24

BN -402 AWG12 BK
3

19
19

OGBU -403 AWG12 BK

4

26
26
MAIN SERVO DRIVE UNIT

GNWH -404 AWG12 BK

5

18
18

OGBK -405 AWG12 BK

2

25
25

Approved by, date:

-X12

BKBU -418 AWG12 BK

1

1
1
DC-BUSBAR

BKRD -420 AWG12 BK

3

10
10
4

BKGN -422 AWG12 BK

5

2
2
6
3

-X13

GYWH -406 AWG12 BK

1

23
23

BNWH -407 AWG12 BK

2

32
32

GY -408 AWG12 BK
3

21
21

BNGN -409 AWG12 BK

4

30
30

GYRD -410 AWG12 BK

5

22
22

BNRD -411 AWG12 BK

6
4

31
31

EPLAN
-X14

GYBU -424 AWG12 BK

1

20
20
2

GYGN -425 AWG12 BK

3

29
29

Lab/Office:
4

GYBK -426 AWG12 BK

5

28
28
6
5

-X15

BU -412 AWG12 BK
1

3
3
BKWH -413 AWG12 BK

IRB 6600-7600
2

4
4
BNBU -414 AWG12 BK
3

7
7
BK -415 AWG12 BK
4

14
14

SERVO DRIVE SYSTEM

BNBK -416 AWG12 BK
5

5
5
6

BUBK -417 AWG12 BK

6

6
6
-X16

BUWH -428 AWG12 BK

1

9
9
2

BUGN -430 AWG12 BK

3

16
16
4

BURD -432 AWG12 BK

8
8
5

Status:
6
7

AWG10 GNYE

Document no.
AWG10 GNYE

Approved
Plant:
Location:
Sublocation: +
= DM
8

3HAC020538-002 02
+ ORT
MANIPULATOR
DRIVE MODULE

Next 5
Rev. Ind Page 4

Total 15
 1 2 3 4 5 6 7 8

DRIVE
AXIS COMPUTER UNIT MANIPULATOR
MODULE
=DM
+A42

-X4 -XS/XP2 -R1.SMB

SDI
1 A A
SDI-N
2 B B
SDO SERIAL
4 C C MEASUREMENT
SDO-N BOARD
5 D D
0V
6 E E
24V
7 F F
BAT BR
3 G G
BAT BR
H H
0V
8 J J
BATSUP
K K
EXT.LAMP EXT.LAMP
L L
-Y1
-C1

-X40 EXT LAMP -433 AWG16 BU 34

0,00
1
BRAKE PB -434 AWG16 BU
-XS/XP1 OGRD
-R1.MP
DRIVE MODULE BRAKE PB
XP40 4 11 11
BRAKE REL. -435 AWG16 BU OG BRAKE RELEASE
2 13 13 BRAKE RELEASE
BRAKE REL. -436 AWG16 BU
3

CONTACTOR UNIT
=DM
-X5 0V BRAKE -437 AWG16 BU OGWH
+A43 0V BRAKE

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0V BRAKE
PTC -439 AWG16 BU PKBK PTC
1 27 27
PTC 0V -440 AWG16 BU PKWH 0V PTC
2 15 15
0V BRAKE -438 AWG16 BU
3

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 1 2 3 4 5 6 7 8

Customer CONTROL MANIPULATOR

Connection MODULE IRB 6600, 7600
AWG 24 OG
-XS/XP8
-XP/XT8.1
-601 OG
-R1.SW1
A
1 A A
-602 OG
2 B B
-603 OG
3 C C
-604 OG
4 D D
-605 OG
5 E E
-606 OG
6 F F
-607 OG
7 G G
-608 OG
8 H H
-609 OG
9 J J
-610 OG
10 K K
-611 OG
11 L L
-612 OG
12 M M

-XP/XT8.2
-613 OG
13 N N
-614 OG
14 P P
-615 OG
15 R R
-616 OG
16 S S
-617 OG
17 T T
-618 OG
18 U U
-619 OG
19 V V

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-620 OG

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20 W W
-621 OG
21 X X
-622 OG
22 Y Y
-623 OG
23 Z Z
-624 OG
24 a a

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 1 2 3 4 5 6 7 8

Customer CONTROL MANIPULATOR

Connection MODULE IRB 6600, 7600
-XS/XP58
AWG 24 OG
-XP/XT58.1
601 -R1.SW23
1 A A
602
2 B B
603
3 C C
604
4 D D
605
5 E E
606
6 F F
607
7 G G
608
8 H H
609
9 J J
610
10 K K
611
11 L L
612
12 M M

-XP/XT58.2
613
13 T T
614
14 U U
615
15 V V
616
16 W W
617
17 X X
618
18 Y Y
619
19 Z Z
620

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20 a a

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621
21 b b
622
22 c c
623
23 d d
624
24 e e

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 1 2 3 4 5 6 7 8

MANIPULATOR
=DM
+BOX
R1.XS.SW23
-R1.XP.SW23 -R1.SW23
A A
B B
C C
D D

E E
F F
G G
H H

J J
K K
L L
M M

T T
U U
V V
DRIVE W W

MODULE
X X
Y Y
Z Z
a a
CONTACTOR UNIT
=DM b b
+A43 c c
d d
e e
-X10
1 S S

2 i i

3
-R1FAN.SW23
24V FAN 1
4 N N
0V FAN 1
P P
T1
-X11
R R

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1

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24V FAN 2
2 f f
0V FAN 2
3 g g
T2
4 h h

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 1 2 3 4 5 6 7 8

MANIPULATOR

-R1.SW23
A
B
C
D

E
F
G
H

J
K
L
M

T
U
V
DRIVE W

MODULE
X
Y
Z
a
CONTACTOR UNIT
=DM b
+A43 c
d
e
-X10
1 S

2 i

3
24V FAN 1
4 N
0V FAN 1
P
T1
-X11
R
1

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24V FAN 2
2 f
0V FAN 2
3 g
T2
4 h

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 1 2 3 4 5 6 7 8

CONTROL MODULE
MANIPULATOR
Customer IRB 6600-7600
-XS/XP13
Connection AWG 18 OG
-XP/XT6
670 -R1.CP/CS
CP4
1 A1 D1
671 CP5
2 A2 D6
672 CP6
3 A3 D3
673 CP7
4 A4 D4
674 CP1
5 A5 D5
675 CP2
6 A6 D2
676 CP3
7 A7 D7
AWG 14 OG
AWG 24 OG
-XP/XT5.1
677 CS
1 678 B1 B1 CS
2 679 B2 B2 CS
3 680 B11 B11 CS
4 681 B12 B12 CS
5 682 B13 B13 CS
6 683 B14 B14 CS
7 684 B15 B15 CS
8 685 B16 B16 CS
9 686 B18 B18 CS
10 687 B19 B19 CS
11 688 B20 B20 CS
12 B21 B21

-XP/XT5.2
695 CS
19 696 C1 C1 CS
20 699 C2 C2 CS
23 700 C3 C3 CS
24 C4 C4

689 CS
13 690 B7 B7 CS
14 691 B8 B8 CS
15 692 B9 B9 CS

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16 693 B10 B10 CS

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17 694 B3 B3 CS
18 697 B4 B4 CS
21 698 B5 B5 CS
22 B6 B6

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 1 2 3 4 5 6 7 8

CONTROL MODULE
MANIPULATOR
Customer IRB 6600-7600
-XS/XP13
Connection AWG 18 OG
-XP/XT6
670 -R1.CP/CS
CP4
1 A1 D1
671 CP5
2 A2 D6
672 CP6
3 A3 D3
673 CP7
4 A4 D4

AWG 24 OG
-XP/XT5.1
677 CS
1 678 B1 B11 CS
2 679 B2 B12 CS
3 680 B3 B13 CS
4 681 B4 B14 CS
5 682 B5 B15 CS
6 683 B6 B16 CS
7 684 B7 B18 CS
8 685 B8 B19 CS
9 686 B9 B20 CS
10 687 B10 B21 CS
11 688 B11 B9 CS
12 B12 B10

-XP/XT5.2
689 CS
13 690 F5 A5 CS
14 691 F6 A6 CS
15 692 F7 A9 CS
16 693 F8 A10 CS
17 694 F9 A11 CS
18 695 F10 A12 CS
19 696 F11 B24 CS
20 F12 B25

DEVICE NET ADAPTER

=CM
-J1
+A35 CAN_L CAN_L
2 1 F4 A4

120 Ohm

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
2
CAN_H

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CAN_H
4 F3 A3
3

CONTROL 701 +24V CAN +24V CAN

MODULE F1 B22
702 0V 0V
G4.X2
F2 B23

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 1 2 3 4 5 6 7 8

CONTOL MODULE MANIPULATOR

Customer IRB 6600-7600
-XS/XP13
Connection AWG 18 OG
-XP/XT6
670 -R1.CP/CS
CP4
1 A1 D1
671 CP5
2 A2 D6
672 CP6
3 A3 D3
673 CP7
4 A4 D4

AWG 24 OG
-XP/XT5.1
677 CS1
1 678 B1 B11 CS2
2 679 B2 B12 CS11
3 680 B3 B13 CS12
4 681 B4 B14 CS13
5 682 B5 B15 CS14
6 683 B6 B16 CS15
7 684 B7 B18 CS16
8 685 B8 B19 CS17
9 686 B9 B20 CS18
10 687 B10 B21 CS19
11 688 B11 B9 CS20
12 B12 B10

-XP/XT5.2
689 CS7
13 690 F5 A5 CS8
14 691 F6 A6 CS9
15 692 F3 A3 CS10
16 693 F4 A4 CS11
17 694 F2 B23 CS3
18 695 F11 B24 CS4
19 F12 B25

DO DO

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
DO_N F7 A9 DO_N

We reserve all rights in this document and in the information contained therein.Reproduction, use or
CONTROL
MODULE DI F8 A10 DI
DI_N F9 A11 DI_N
A38.2.X2
GND F10 A12 GND
GND F1 B22

Latest revision: Lab/Office: Status: Plant: = CM

Approved Location: + ORT
EPLAN Sublocation: +
CUSTOMER POWER/SIGNALS/IBS Document no. Rev. Ind Page 12
Next 13
Prepared by, date: Approved by, date: IRB 6600-7600 3HAC020538-002 02 Total 15
 1 2 3 4 5 6 7 8

CONTROL MODULE MANIPULATOR

Customer IRB 6600-7600
-XS/XP13
Connection AWG 18 OG
-XP/XT6
670 -R1.CP/CS
CP4
1 A1 D1
671 CP5
2 A2 D6
672 CP6
3 A3 D3
673 CP7
4 A4 D4

AWG 24 OG
-XP/XT5.1
677 CS
1 678 B1 B11 CS
2 679 B2 B12 CS
3 680 B3 B13 CS
4 681 B4 B14 CS
5 682 B5 B15 CS
6 683 B6 B16 CS
7 684 B7 B18 CS
8 685 B8 B19 CS
9 686 B9 B20 CS
10 687 B10 B21 CS
11 688 B11 B9 CS
12 B12 B10

-XP/XT5.2
689 CS
13 690 F3 A3 CS
14 691 F4 A4 CS
15 692 F7 A9 CS
16 693 F8 A10 CS
17 694 F9 A11 CS
18 695 F10 A12 CS
19 696 F11 B24 CS
20 697 F12 B25 CS
21 698 F1 B22 CS
22 F2 B23

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
CONTROL RD RXD/TXD-P RXD/TXD-P
MODULE F5 A5

A33.X3 GN RXD/TXD-N RXD/TXD-N

F6 A6

Latest revision: Lab/Office: Status: Plant: = CM

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CUSTOMER POWER/SIGNALS/PROFIBUS Document no. Rev. Ind Page 13
Next 14
Prepared by, date: Approved by, date: IRB 6600-7600 3HAC020538-002 02 Total 15
 1 2 3 4 5 6 7 8

SINGLE SERVO DRIVE UNIT

=DM -XS/XP7
-X21 4000 AWG12 BK
+A41.1.3 U
1 A1
U 4001 AWG12 BK
2 A2
W 4002 AWG12 BK
3 A3
W 4003 AWG12 BK
4 A4
V 4004 AWG12 BK
5 A5
V 4005 AWG12 BK
6 A6

CONTACTOR UNIT
=DM
-X24 4013 AWG16 BU
+A43 PTC
1 E1
PTC 0V 4014 AWG16 BU
2 E2

3 E3

4 E4

5 E5

6 E6
0V BRAKE -4012 AWG16 BU
F9

F10

F11
-X22 -4006 AWG16 BU
LIM2 ch1
1 F1
LIM2 ch1 ret -6007 AWG16 BU
2 F4
LIM2 ch2 -4008 AWG16 BU
3 F2
LIM2 ch2 ret -4009 AWG16 BU
4 F3

-XS40
-445
1 -447 F5
2 -448

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
3 F6

We reserve all rights in this document and in the information contained therein.Reproduction, use or
-446
4 BRAKE REL. +24V -4010 AWG16 BU
5 BRAKE PB -4011 AWG16 BU F7
6
DRIVE MODULE F8
X40 -XP40 AWG16 BU AWG10 GNYE
1
AWG16 BU
2
AWG16 BU
3
AWG16 BU
4

Latest revision: Lab/Office: Status: Plant: = DM

Approved Location: + ORT
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EXTERNAL AXIS no 7 Document no. Rev. Ind Page 14
Next 15
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 15
 1 2 3 4 5 6 7 8

FOR 8 AXIS

SINGLE SERVO DRIVE UNIT

=DM -XS/XP7
-X21 -4000 AWG12
+A41.1.4 U
1 B1
U -4001 AWG12
2 B2
W -4002 AWG12
3 B3
W -4003 AWG12
4 B4
V -4004 AWG12
5 B5
V -4005 AWG12
6 B6

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = DM
Approved Location: + ORT
EPLAN Sublocation: +
EXTERNAL AXIS no 8 Document no. Rev. Ind Page 15
Next
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 15
 1 2 3 4 5 6 7 8

EPLAN

The information in this document is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

In no event shall ABB be liable for incidental or consequential damages arising from use of this document
or of the software and hardware described in this document.

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

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

© Copyright 2004 ABB All right reserved.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
ABB Automation Technologies AB

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Robotics
SE-721 68 Västerås
Sweden

Latest revision: Lab/Office: Status: Plant: = DOKUMENTE

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EPLAN Sublocation: +
Title page Document no. Rev. Ind Page 1
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Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

EPLAN

Phone :

Customer :
Robot serial number(s) :
Drawing number : 3HAC020538-002_Cables for 4400
Drawing version :
Manufacture : 2004-09-23
Type :
Type of installation :
Control cabinet :
Mains voltage :
Supply :
Control voltage :
Year of construction :

Project start : 2004-02-16

Project manager :
Last revision :

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Designed by : jsundin1

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Designed date : 2004-09-23
Number of pages : 9
:

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Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

Table of contents DIN_INV_30_1

Plant Location Page Page description Page supplementary field Date Editor
DOKUMENTEDKB 1 Title page Approved 2004-09-09 jsundin1
DOKUMENTEDKB 2 Title page Approved 2004-09-09 jsundin1
DOKUMENTEINV 3 Table of contents: (1 - 9) Approved 2004-09-23 jsundin1
DM ORT 4 SERVO DRIVE SYSTEMIRB 4400 Approved 2004-09-23 jsundin1
DM ORT 5 CONTROL CABLEIRB 4400 Approved 2004-09-23 jsundin1
CM ORT 6 CUSTOMER POWER/SIGNALIRB 4400 Approved 2004-09-23 jsundin1
CM ORT 7 POSITION SWITCHIRB 4400 Approved 2004-09-23 jsundin1
DM ORT 8 EXTERNAL AXIS no 7 Approved 2004-09-23 jsundin1
DM ORT 9 EXTERNAL AXIS no 8 Approved 2004-09-23 jsundin1

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
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 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
54
0,00

Latest revision:
1

Prepared by, date:

=CAB
+A41.1

-R1.MP
-XS/XP1
-X11

M1R BKBU -400 AWG16

1

M1R BKGN -401 AWG16

A1
A1
2

M1T BUGN -402 AWG16

A2
A2
3

M1T BURD -403 AWG16

A5
A5
4

M1S BKWH -404 AWG16

A6
A6
5

M1S BK -405 AWG16

A3
A3
6

M1R BKRD
A4
A4

M1S BUBK
D6
D6
2

MAIN SERVO DRIVE UNIT

M1T BUWH
D8
D8

D10
D10

Approved by, date:

-X12

M4R GYWH -418 AWG16 BK

1

B3
B3
2

M4T OGGN -420 AWG16 BK

3

B5
B5
4

M4S OGBK -422 AWG16 BK

5

B4
B4
6

M4R GYRD
M4S GY
3

D11
D11

OGBU
DC-BUSBAR

M4T
D12
D12

D13
D13
-X13

M2R BU -406 AWG16

1

M2R BNBK -407 AWG16

A7
A7
2

M2T BNRD -408 AWG16

A8
A8
3

M2T BNWH -409 AWG16

A11
A11
4

M2S BNBU -410 AWG16

A12
A12
5

M2S BNGN -411 AWG16

A9
A9
6

A10
A10
4

-X14

EPLAN
M5R OGWH -424 AWG16 BK
1

B6
B6
2

M5T PKGN -425 AWG16 BK

3

B8
B8
4

M5S PKBK -426 AWG16 BK

5

B7
B7
6

M5R OGRD

Lab/Office:
M5S OG

D14
D14

M5T PKBU

D15
D15

D16
D16
5

-X15

M3R BN -412 AWG16

IRB 4400
1

M3R GNRD -413 AWG16

A13
A13
2

M3T GYBU -414 AWG16

A14
A14
3

M3T GYGN -415 AWG16

B1
B1
4

M3S GNWH -416 AWG16

B2
B2
5

M3S GYBK -417 AWG16

A15
A15
6

WHBU

A16
A16
WHGN

C13
C13
WHRD

C14
C14

SERVO DRIVE SYSTEM

C15
C15
-X16
6

M6R PKRD -428 AWG16 BK

1

B9
B9
2

M6T PK -430 AWG16 BK

3

B11
B11
4

M6S PKWH -432 AWG16 BK

5

AWG10

B10
B10
6

AWG10

Status:
C3
7

C4

Document no.
Approved
C5
C6
C7
C8
C9
C10

Plant:
C11
C12

Location:
Sublocation: +
DRIVE MODULE

= DM
8

3HAC020538-002 02
+ ORT
MANIPULATOR

Total 9
Next 5
Rev. Ind Page 4
 1 2 3 4 5 6 7 8

AXIS COMPUTER UNIT DRIVE MODULE MANIPULATOR

=CAB
+A42

-X4 -XS/XP2 -R1.SMB

SDI
1 A A SDI-N
2 B B SDO
4 C C SDO-N
5 D D 0V SERIAL
6 E E MEASUREMENT
24V BOARD
7 F F

3 G G
H H 0V
9 J J BATSUP
K K BATLD
L L

54
0,00
-XS/XP40 Ext. Lamp -433 AWG16 BU
-XS/XP1 WH
-R1.MP
1 C16 C16
DRIVE MODULE Brake PB -434 AWG16 BU VT

X40 4 B16 B16

Brake Release -435 AWG16 BU RDBK
2 B12 B12
Brake Release -436 AWG16 BU RDBU
3 B13 B13
CONTACTOR UNIT
=CAB
-X5 0V Brake -438 AWG16 BU RDGN
+A43
4 B14 B14
PTC -439 AWG16 BU VTGN
1 C2 C2
PTC 0V -440 AWG16 BU VTBU
2 C1 C1
0V Brake -437 AWG16 BU VTWH
3 B15 B15

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-X21 LIM 1A -441 AWG16 BU RD

We reserve all rights in this document and in the information contained therein.Reproduction, use or
2 D2 D2
LIM 2A -442 AWG16 BU RDWH
4 1) D1 D1
LIM 2B -443 AWG16 BU VTBK
3 D3 D3
LIM 1B -444 AWG16 BU VTRD
1 D4 D4

1) Jumper if not used.

Latest revision: Lab/Office: Status: Plant: = DM
Approved Location: + ORT
EPLAN Sublocation: +
CONTROL CABLE Document no. Rev. Ind Page 5
Next 6
Prepared by, date: Approved by, date: IRB 4400 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

CONTROL MODULE MANIPULATOR

Customer IRB 4400
=CAB-XS/XP5
Connection AWG 18 OG
=CAB-XP/XT6
648 =CAB-R1.CP/CS
CPA
1 649 A1 A1 CPB
2 650 B1 B1 CPC
3 651 C1 C1 CPD
4 652 D1 D1 CPE
5 653 A2 A2 CPF
6 654 B2 B2 CPJ
7 655 C2 C2 CPK
8 656 D2 D2 CPL
9 657 A3 A3 CPM
10 658 B3 B3
11 659 C3 C3
12 D3 D3

AWG 24 OG
=CAB-XP/XT5.1
625 CSA
1 626 B5 B5 CSB
2 627 C5 C5 CSC
3 628 D5 D5 CSD
4 629 A6 A6 CSE
5 630 B6 B6 CSF
6 631 C6 C6 CSG
7 632 D6 D6 CSH
8 633 A7 A7 CSJ
9 634 B7 B7 CSK
10 635 C7 C7 CSL
11 636 D7 D7 CSM
12 A8 A8

=CAB-XP/XT5.2
637 CSN
13 638 B8 B8 CSP
14 639 C8 C8 CSR
15 640 D8 D8 CSS
16 641 A9 A9 CST
17 642 B9 B9 CSU
18 643 C9 C9 CSV
19 644 D9 D9 CSW
20 645 A10 A10 CSX

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
21 646 B10 B10 CSY

We reserve all rights in this document and in the information contained therein.Reproduction, use or
22 647 C10 C10 CSZ
23 C10
D10 D10

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Prepared by, date: Approved by, date: IRB 4400 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

CONTROL MODULE
Customer MANIPULATOR
Connection IRB 4400

=CAB-XS/XP8
=CAB-XP/XT8
-601 OG
=CAB-R1.SW
1 A A
1
-602 OG
2 B B
-603 OG
3 C C
-604 OG
4 D D
-605 OG
5 E E
-606 OG
6 F F
-607 OG
7 J J
-608 OG
8 K K
-609 OG
9 L L
-610 OG
10 M M
-611 OG
11 G G
-612 OG
12 H H

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = CM
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POSITION SWITCH Document no. Rev. Ind Page 7
Next 8
Prepared by, date: Approved by, date: IRB 4400 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

SINGLE SERVO DRIVE UNIT

=CAB -XS/XP7
-X21 -4000 AWG12 BK
+A41.1.3 U
1 A1
U -4001 AWG12 BK
2 A2
W -4002 AWG12 BK
3 A3
W -4003 AWG12 BK
4 A4
V -4004 AWG12 BK
5 A5
V -4005 AWG12 BK
6 A6

CONTACTOR UNIT
=CAB
-X24 -4013 AWG16 BU
+A43 PTC
1 E1
PTC 0V -4014 AWG16 BU
2 E2

3 E3

4 E4

5 E5

6 E6
0V BRAKE -4012 AWG16 BU
F9

F10

F11
-X22 -4006 AWG16 BU
LIM2 ch1
1 F1
LIM2 ch1 ret -4007 AWG16 BU
2 F4
LIM2 ch2 -4008 AWG16 BU
3 F2
LIM2 ch2 ret -4009 AWG16 BU
4 F3

-XS40
1 F5
2

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
3 F6

We reserve all rights in this document and in the information contained therein.Reproduction, use or
4 BRAKE REL. +24V -4010 AWG16 BU
5 BRAKE PB BU F7
6 -4011 AWG16 F8
DRIVE MODULE
X40
AW G16 BU
-XP40 -445
1
-447 AW G16 BU
2
-448 AW G16 BU
3
-446 AW G16 BU
4

Latest revision: Lab/Office: Status: Plant: = DM

Approved Location: + ORT
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EXTERNAL AXIS no 7 Document no. Rev. Ind Page 8
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Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

FOR 8 AXIS

SINGLE SERVO DRIVE UNIT

=CAB -XS/XP7
-X21 4000 AWG12
+A41.1.4 U
1 B1
U 4001 AWG12
2 B2
W 4002 AWG12
3 B3
W 4003 AWG12
4 B4
V 4004 AWG12
5 B5
V 4005 AWG12
6 B6

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = DM
Approved Location: + ORT
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EXTERNAL AXIS no 8 Document no. Rev. Ind Page 9
Next
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

EPLAN

The information in this document is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

In no event shall ABB be liable for incidental or consequential damages arising from use of this document
or of the software and hardware described in this document.

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

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

© Copyright 2004 ABB All right reserved.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
ABB Automation Technologies AB

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Robotics
SE-721 68 Västerås
Sweden

Latest revision: Lab/Office: Status: Plant: = DOKUMENTE

Approved Location: + DKB
EPLAN Sublocation: +
Title page Document no. Rev. Ind Page 1
Next 2
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 8
 1 2 3 4 5 6 7 8

EPLAN

Phone :

Customer :
Robot serial number(s) :
Drawing number : 3HAC020538-002 Cables for 340
Drawing version :
Manufacture : 2004-09-23
Type :
Type of installation :
Control cabinet :
Mains voltage :
Supply :
Control voltage :
Year of construction :

Project start : 2004-02-16

Project manager :
Last revision :

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Designed by : jsundin1

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Designed date : 2004-09-23
Number of pages : 8
:

Latest revision: Lab/Office: Status: Plant: = DOKUMENTE

Approved Location: + DKB
EPLAN Sublocation: +
Title page Document no. Rev. Ind Page 2
Next 3
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 8
 1 2 3 4 5 6 7 8

Table of contents DIN_INV_30_1

Plant Location Page Page description Page supplementary field Date Editor
DOKUMENTEDKB 1 Title page Approved 2004-09-09 jsundin1
DOKUMENTEDKB 2 Title page Approved 2004-09-09 jsundin1
DOKUMENTEINV 3 Table of contents: (1 - 8) Approved 2004-09-23 jsundin1
DM ORT 4 SERVO DRIVE UNITSIRB 340 Approved 2004-09-23 jsundin1
DM ORT 5 CONTROL CABLEIRB 340 Approved 2004-09-23 jsundin1
CM ORT 6 CUSTOMER SIGNALIRB 340 Approved 2004-09-23 jsundin1
DM ORT 7 EXTERNAL AXIS no 7 Approved 2004-09-23 jsundin1
DM ORT 8 EXTERNAL AXIS no 8-9 Approved 2004-09-23 jsundin1

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = DOKUMENTE
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EPLAN Sublocation: +
Table of contents: (1 - 8) Document no. Rev. Ind Page 3
Next 4
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 8
 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
Latest revision:
1

Prepared by, date:

2

+A41.1
=DM

0,00
32

Approved by, date:

-XS/XP1

-R1-MP 1-3
-X17

BKWH -400 AWG16 BK

1

9
A11

BK -402 AWG16 BK
2
MAIN SERVO DRIVE UNIT

11
A9

BUBK -404 AWG16 BK

3

13
A7

BKRD -410 AWG16 BK

4

3
A5

-R1.MP 4-6

BKGN -408 AWG16 BK

5

1
B3

BKBU -406 AWG16 BK

6

2
B4
4

-X19
DC-BUSBAR

BUGN -418 AWG16 BK

1

EPLAN
B10

BURD -420 AWG16 BK

2

6
B9

BUWH -422 AWG16 BK

3

10
B8

BNBU -416 AWG16 BK

4

13

Lab/Office:
A13

BNBK -414 AWG16 BK

5

17
A15

BU -412 AWG16 BK
6

15
B1
5

IRB 340
AWG10 GNYE
AWG10 GNYE

SERVO DRIVE UNITS

6

Status:
7

Document no.
DRIVE MODULE

Approved
MANIPULATOR

Plant:
Location:
Sublocation: +
= DM
8

3HAC020538-002 02
+ ORT

Total 8
Next 5
Rev. Ind Page 4
 1 2 3 4 5 6 7 8

AXIS COMPUTER UNIT DRIVE MODULE MANIPULATOR

=DM
+A42

-X4 -XS/XP2 -R1.SMB

SDI
1 A A SDI-N
2 B B SDO
4 C C SDO-N
5 D D 0V SERIAL
6 E E MEASUREMENT
24V BOARD
7 F F

3 G G
H H 0V
9 J J BATSUP
K K BATLD
L L

32
0,00
-XS/XP40 Ext. Lamp -433 AWG16 BU
-XS/XP1 GY
-R1.MP
DRIVE MODULE 1 C7 C7

X40 Brake PB -434 AWG16 BU GNWH

4 B16 B8
Brake Release -435 AWG16 BU BNRD
2 B12 C9
Brake Release -436 AWG16 BU BNGN
3 B13 C8
CONTACTOR UNIT
=DM
-X5 0V Brake -438 AWG16 BU BNWH
+A43
4 B14 C10
PTC -439 AWG16 BU BN
1 C2 B9
PTC 0V -440 AWG16 BU GYBK
2 C1 B2
0V Brake -437 AWG16 BU GNRD
3 B15 B7

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-X21 GYBU
LIM 1A
2 D2 B3
LIM 2A GYRD
4 D1 B4
LIM 2B GYWH
3 D3 C2
LIM 1B GYGN
1 D4 C1

Latest revision: Lab/Office: Status: Plant: = DM

Approved Location: + ORT
EPLAN Sublocation: +
CONTROL CABLE Document no. Rev. Ind Page 5
Next 6
Prepared by, date: Approved by, date: IRB 340 3HAC020538-002 02 Total 8
 1 2 3 4 5 6 7 8

CONTROL MODULE
Customer MANIPULATOR
Connection IRB 340

AWG 24 OG

-XS/XP5
-XP/XT5
625 -R1.CS
CSA
1 B5
A A
1
626 CSB
2 C5 B
627 CSC
3 D5 C
628 CSD
4 A6 D
629 CSE
5 B6 E
630 CSF
6 C6 F
631 CSG
7 D6 G
632 CSH
8 A7 H
633 CSJ
9 B7 J
634 CSK
10 C7 K
635 CSL
11 D7 L
636 CSM
12 A8 M

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = CM
Approved Location: + ORT
EPLAN Sublocation: +
CUSTOMER SIGNAL Document no. Rev. Ind Page 6
Next 7
Prepared by, date: Approved by, date: IRB 340 3HAC020538-002 02 Total 8
 1 2 3 4 5 6 7 8

SINGLE SERVO DRIVE UNIT

=DM -XS/XP7
-X21 -4000 AWG12 BK
+A41.1.3 U
1 A1
U -4001 AWG12 BK
2 A2
W -4002 AWG12 BK
3 A3
W -4003 AWG12 BK
4 A4
V -4004 AWG12 BK
5 A5
V -4005 AWG12 BK
6 A6

CONTACTOR UNIT
=DM
-X24 -4013 AWG16 BU
+A43 PTC
1 E1
PTC 0V -4014 AWG16 BU
2 E2

3 E3

4 E4

5 E5

6 E6
0V BRAKE -4012 AWG16 BU
F9

F10

F11
-X22 -4006 AWG16 BU
LIM2 ch1
1 F1
LIM2 ch1 ret -4007 AWG16 BU
2 F4
LIM2 ch2 -4008 AWG16 BU
3 F2
LIM2 ch2 ret -4009 AWG16 BU
4 F3

-XS40 EXT. LAMP

1 BRAKE REL. F5
2 BRAKE REL.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
3 BRAKE PB F6

We reserve all rights in this document and in the information contained therein.Reproduction, use or
4 BRAKE REL. +24V -4010 AWG16 BU
5 BRAKE PB -4011 AWG16 BU F7
DRIVE MODULE 6 F8

X40
AW G16 BU AWG10 GNYE
-XP40 -445
1
-447 AW G16 BU
2
-448 AW G16 BU
3
-446 AW G16 BU
4

Latest revision: Lab/Office: Status: Plant: = DM

Approved Location: + ORT
EPLAN Sublocation: +
EXTERNAL AXIS no 7 Document no. Rev. Ind Page 7
Next 8
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 8
 1 2 3 4 5 6 7 8

FOR 8 AXIS

SINGLE SERVO DRIVE UNIT

=DM -XS/XP7
-X21 -4000 AWG12
+A41.1.4 U
1 B1
U -4001 AWG12
2 B2
W -4002 AWG12
3 B3
W -4003 AWG12
4 B4
V -4004 AWG12
5 B5
V -4005 AWG12
6 B6

FOR 9 AXIS
SINGLE SERVO DRIVE UNIT
=DM -XS/XP7
-X21 -4000 AWG12
+A41.1.5 U
1 C1
U -4001 AWG12
2 C2
W -4002 AWG12
3 C3
W -4003 AWG12
4 C4
V -4004 AWG12
5 C5
V -4005 AWG12

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
6 C6

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = DM
Approved Location: + ORT
EPLAN Sublocation: +
EXTERNAL AXIS no 8-9 Document no. Rev. Ind Page 8
Next
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 8
 1 2 3 4 5 6 7 8

EPLAN

The information in this document is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

In no event shall ABB be liable for incidental or consequential damages arising from use of this document
or of the software and hardware described in this document.

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

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

© Copyright 2004 ABB All right reserved.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
ABB Automation Technologies AB

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Robotics
SE-721 68 Västerås
Sweden

Latest revision: Lab/Office: Status: Plant: = DOKUMENTE

Approved Location: + DKB
EPLAN Sublocation: +
Title page Document no. Rev. Ind Page 1
Next 2
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

EPLAN

Phone :

Customer :
Robot serial number(s) :
Drawing number : 3HAC020538-002_Cables for 2400
Drawing version :
Manufacture : 2004-09-23
Type :
Type of installation :
Control cabinet :
Mains voltage :
Supply :
Control voltage :
Year of construction :

Project start : 2004-02-16

Project manager :
Last revision :

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Designed by : jsundin1

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Designed date : 2004-09-23
Number of pages : 9
:

Latest revision: Lab/Office: Status: Plant: = DOKUMENTE

Approved Location: + DKB
EPLAN Sublocation: +
Title page Document no. Rev. Ind Page 2
Next 3
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

Table of contents DIN_INV_30_1

Plant Location Page Page description Page supplementary field Date Editor
DOKUMENTEDKB 1 Title page Approved 2004-09-09 jsundin1
DOKUMENTEDKB 2 Title page Approved 2004-09-09 jsundin1
DOKUMENTEINV 3 Table of contents: (1 - 9) Approved 2004-09-23 jsundin1
DM ORT 4 SERVO DRIVE UNITIRB 2400 Approved 2004-09-23 jsundin1
DM ORT 5 CONTROL CABLEIRB 2400 Approved 2004-09-23 jsundin1
CM ORT 6 CUSTOMER POWER/SIGNALIRB 2400 Approved 2004-09-23 jsundin1
CM ORT 7 POSITION SWITCHIRB 2400 Approved 2004-09-23 jsundin1
DM ORT 8 EXTERNAL AXIS no 7 Approved 2004-09-23 jsundin1
DM ORT 9 EXTERNAL AXIS no 8-9 Approved 2004-09-23 jsundin1

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = DOKUMENTE
Approved Location: + INV
EPLAN Sublocation: +
Table of contents: (1 - 9) Document no. Rev. Ind Page 3
Next 4
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 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
Latest revision:
1

Prepared by, date:

=DM
+A41.1

0,00
32

-R1.MP
-XS/XP1
-X17

M1R BKBU -400 AWG14 BK

1

A1
A1

M1S BKGN -402 AWG14 BK

2

A2
A3

M1T BKRD -404 AWG14 BK

2

A3
A5
MAIN SERVO DRIVE UNIT

M2T BUBK -410 AWG14 BK

4

D2
A11

M2S BK -408 AWG14 BK

Approved by, date:
5

A9

D1

M2R BKWH -406 AWG14 BK

6

A4
A7
3

-X18

M4R BU -418 AWG14 BK

1

B3

A10

M4S BNBK -420 AWG14 BK

2

A9
B4

BNBU AWG14 BK
DC-BUSBAR

M4T -422
3

A8
B5

M6T GNWH -432 AWG14 BK

4

B10
B11

M6S GNRD -430 AWG14 BK

5
4

D7
B10

M6R BN -428 AWG14 BK

6

EPLAN
B9

D8

Lab/Office:
-X19

M3R BUGN -412 AWG14 BK

1

D3
A13

M3S BURD -414 AWG14 BK

2

D4
A15
5

M3T BUWH -416 AWG14 BK

3

B1
B1
M5T BNWH -426 AWG14 BK

IRB 2400
4

B8

D9
M5S BNRD -425 AWG14 BK
5

B7

D10
M5R BNGN -424 AWG14 BK
6

A7
B6

SERVO DRIVE UNIT

AWG10 GNYE
6

AWG10 GNYE

Status:
7

Document no.
Approved
MANIPULATOR
DRIVE MODULE

Plant:
Location:
Sublocation: +
= DM
8

3HAC020538-002 02
+ ORT

Total 9
Next 5
Rev. Ind Page 4
 1 2 3 4 5 6 7 8

AXIS COMPUTER UNIT DRIVE MODULE MANIPULATOR

=DM
+A42

-X4 -XS/XP2 -R1.SMB

SDI
1 A A SDI-N
2 B B SDO
4 C C SDO-N
5 D D 0V SERIAL
6 E E MEASUREMENT
24V BOARD
7 F F

3 G G
H H 0V
9 J J BATSUP
K K BATLD
L L

32

-XS/XP40 Ext. Lamp -433 AW G16 BU

-XS/XP1 OG
-R1.MP
DRIVE MODULE 1 C7 C7

X40 Brake PB -434 AW G16 BU OGWH

4 B16 B8
Brake Release -435 AW G16 BU GYBK
2 B12 C9
Brake Release -436 AW G16 BU GYBU
3 B13 C8
CONTACTOR UNIT
=DM
-X5 0V Brake -438 AW G16 BU GYGN
+A43
4 B14 C10
PTC -439 AW G16 BU OGBU
1 C2 B9
PTC 0V -440 AW G16 BU OGBK
2 C1 B2
0V Brake -437 AW G16 BU OGRD
3 B15 B7

-X21 LIM 1A -441 AW G16 BU GYRD

2 D1 B3

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
LIM 2A -442 AW G16 BU GYWH

We reserve all rights in this document and in the information contained therein.Reproduction, use or
4 1) D2 B4
LIM 2B -443 AW G16 BU GY
3 D3 C2
LIM 1B -444 AW G16 BU OGGN
1 D4 C1

1) Jumper if note used.

Latest revision: Lab/Office: Status: Plant: = DM

Approved Location: + ORT
EPLAN Sublocation: +
CONTROL CABLE Document no. Rev. Ind Page 5
Next 6
Prepared by, date: Approved by, date: IRB 2400 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

CONTROL MODULE MANIPULATOR

Customer IRB 2400
-XS/XP5
Connection AWG 18 OG
-XP/XT6
648 -R1.CP/CS
CPA
1 649 A1 A1 CPB
2 650 B1 B1 CPC
3 651 C1 C1 CPD
4 652 D1 D1 CPE
5 653 A2 A2 CPF
6 654 B2 B2 CPJ
7 655 C2 C2 CPK
8 656 D2 D2 CPL
9 657 A3 A3 CPM
10 658 B3 B3
11 659 C3 C3
12 D3 D3

AWG 24 OG
-XP/XT5.1
625 CSA
1 626 B5 B5 CSB
2 627 C5 C5 CSC
3 628 D5 D5 CSD
4 629 A6 A6 CSE
5 630 B6 B6 CSF
6 631 C6 C6 CSG
7 632 D6 D6 CSH
8 633 A7 A7 CSJ
9 634 B7 B7 CSK
10 635 C7 C7 CSL
11 636 D7 D7 CSM
12 A8 A8

-XP/XT5.2
637 CSN
13 638 B8 B8 CSP
14 639 C8 C8 CSR
15 640 D8 D8 CSS
16 641 A9 A9 CST
17 642 B9 B9 CSU
18 643 C9 C9 CSV
19 644 D9 D9 CSW
20 645 A10 A10 CSX

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
21 646 B10 B10 CSY

We reserve all rights in this document and in the information contained therein.Reproduction, use or
22 647 C10 C10 CSZ
23 C10
D10 D10

Latest revision: Lab/Office: Status: Plant: = CM

Approved Location: + ORT
EPLAN Sublocation: +
CUSTOMER POWER/SIGNAL Document no. Rev. Ind Page 6
Next 7
Prepared by, date: Approved by, date: IRB 2400 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

CONTROL MODULE
Customer MANIPULATOR
Connection IRB 2400

-XS/XP8
-XP/XT8
-601 OG
-R1.SW
1 A A
1
-602 OG
2 B B
-603 OG
3 C C
-604 OG
4 D D
-605 OG
5 E E
-606 OG
6 F F
-607 OG
7 J J
-608 OG
8 K K
-609 OG
9 L L
-610 OG
10 M M
-611 OG
11 G G
-612 OG
12 H H

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = CM
Approved Location: + ORT
EPLAN Sublocation: +
POSITION SWITCH Document no. Rev. Ind Page 7
Next 8
Prepared by, date: Approved by, date: IRB 2400 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

SINGLE SERVO DRIVE UNIT

=DM -XS/XP7
-X21 -4000 AWG12 BK
+A41.1.3 U
1 A1
U -4001 AWG12 BK
2 A2
W -4002 AWG12 BK
3 A3
W -4003 AWG12 BK
4 A4
V -4004 AWG12 BK
5 A5
V -4005 AWG12 BK
6 A6

CONTACTOR UNIT
=DM
-X24 -4013 AWG16 BU
+A43 PTC
1 E1
PTC 0V -4014 AWG16 BU
2 E2

3 E3

4 E4

5 E5

6 E6
0V BRAKE -4012 AWG16 BU
F9

F10

F11
-X22 -4006 AWG16 BU
LIM2 ch1
1 F1
LIM2 ch1 ret -4007 AWG16 BU
2 F4
LIM2 ch2 -4008 AWG16 BU
3 F2
LIM2 ch2 ret -4009 AWG16 BU
4 F3

-XS40 EXT. LAMP

1 BRAKE REL. F5
2 BRAKE REL.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
3 BRAKE PB F6

We reserve all rights in this document and in the information contained therein.Reproduction, use or
4 BRAKE REL. +24V -4010 AWG16 BU
5 BRAKE PB BU F7
DRIVE MODULE 6 -4011 AWG16 F8

X40
AWG16 BU AWG10 GNYE
-XP40 -445
1
-447 AWG16 BU
2
-448 AWG16 BU
3
-446 AWG16 BU
4

Latest revision: Lab/Office: Status: Plant: = DM

Approved Location: + ORT
EPLAN Sublocation: +
EXTERNAL AXIS no 7 Document no. Rev. Ind Page 8
Next 9
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

FOR 8 AXIS

SINGLE SERVO DRIVE UNIT

=DM -XS/XP7
-X21 4000 AWG12
+A41.1.4 U
1 B1
U 4001 AWG12
2 B2
W 4002 AWG12
3 B3
W 4003 AWG12
4 B4
V 4004 AWG12
5 B5
V 4005 AWG12
6 B6

FOR 9 AXIS
SINGLE SERVO DRIVE UNIT
=DM -XS/XP7
-X21 4000 AWG12
+A41.1.5 U
1 C1
U 4001 AWG12
2 C2
W 4002 AWG12
3 C3
W 4003 AWG12
4 C4
V 4004 AWG12
5 C5
V 4005 AWG12

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
6 C6

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = DM
Approved Location: + ORT
EPLAN Sublocation: +
EXTERNAL AXIS no 8-9 Document no. Rev. Ind Page 9
Next
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

EPLAN

The information in this document is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

In no event shall ABB be liable for incidental or consequential damages arising from use of this document
or of the software and hardware described in this document.

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

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

© Copyright 2004 ABB All right reserved.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
ABB Automation Technologies AB

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Robotics
SE-721 68 Västerås
Sweden

Latest revision: Lab/Office: Status: Plant: = DOKUMENTE

Approved Location: + DKB
EPLAN Sublocation: +
Title page Document no. Rev. Ind Page 1
Next 2
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

EPLAN

Phone :

Customer :
Robot serial number(s) :
Drawing number : 3HAC020538-002 Cables for 1400
Drawing version :
Manufacture : 2004-09-23
Type :
Type of installation :
Control cabinet :
Mains voltage :
Supply :
Control voltage :
Year of construction :

Project start : 2004-02-16

Project manager :
Last revision :

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Designed by : jsundin1

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Designed date : 2004-09-23
Number of pages : 9
:

Latest revision: Lab/Office: Status: Plant: = DOKUMENTE

Approved Location: + DKB
EPLAN Sublocation: +
Title page Document no. Rev. Ind Page 2
Next 3
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

Table of contents DIN_INV_30_1

Plant Location Page Page description Page supplementary field Date Editor
DOKUMENTEDKB 1 Title page Approved 2004-09-09 jsundin1
DOKUMENTEDKB 2 Title page Approved 2004-09-09 jsundin1
DOKUMENTEINV 3 Table of contents: (1 - 9) Approved 2004-09-23 jsundin1
DM ORT 4 SERVO DRIVE SYSTEMIRB 1400 Approved 2004-09-23 jsundin1
DM ORT 5 CONTROL CABLEIRB 1400 Approved 2004-09-23 jsundin1
CM ORT 6 CUSTOMER SIGNALSIRB 1400 Approved 2004-09-23 jsundin1
CM ORT 7 POSITION SWITCHES Approved 2004-09-23 jsundin1
DM ORT 8 EXTERNAL AXIS no 7 Approved 2004-09-23 jsundin1
DM ORT 9 EXTERNAL AXIS no 8-9 Approved 2004-09-23 jsundin1

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = DOKUMENTE
Approved Location: + INV
EPLAN Sublocation: +
Table of contents: (1 - 9) Document no. Rev. Ind Page 3
Next 4
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 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
Latest revision:
1

Prepared by, date:

=DM
+A41.1

0,00
32

-R1.MP
-XS/XP1
-X17

M1R BKBU -400 AWG14 BK

1

A1
A1

M1S BKGN -402 AWG14 BK

2

A2
A3

M1T BKRD -404 AWG14 BK

2

A3
A5
MAIN SERVO DRIVE UNIT

M2T BUBK -410 AWG14 BK

4

D2
A11

M2S BK -408 AWG14 BK

Approved by, date:
5

A9

D1

M2R BKWH -406 AWG14 BK

6

A4
A7
3

-X18

M4R BU -418 AWG14 BK

1

B3

A10

M4S BNBK -420 AWG14 BK

DC-BUSBAR

A9
B4

M4T BNBU -422 AWG14 BK

3

A8
B5

M6T GNWH -432 AWG14 BK

4

B10
B11

M6S GNRD -430 AWG14 BK

5
4

D7
B10

M6R BN -428 AWG14 BK

6

EPLAN
B9

D8

Lab/Office:
-X19

M3R BUGN -412 AWG14 BK

1

D3
A13

M3S BURD -414 AWG14 BK

2

D4
A15
5

M3T BUWH -416 AWG14 BK

3

B1
B1
M5T BNWH -426 AWG14 BK

IRB 1400
4

B8

D9
M5S BNRD -425 AWG14 BK
5

B7

D10
M5R BNGN -424 AWG14 BK
6

A7
B6

SERVO DRIVE SYSTEM

AWG10 GNYE
6

AWG10 GNYE

Status:
7

Document no.
DRIVE MODULE

Approved
MANIPULATOR

Plant:
Location:
Sublocation: +
= DM
8

3HAC020538-002 02
+ ORT

Total 9
Next 5
Rev. Ind Page 4
 1 2 3 4 5 6 7 8

AXIS COMPUTER UNIT DRIVE MODULE MANIPULATOR

=DM
+A42

-X4 -XS/XP2 -R1.SMB

SDI
1 A A SDI-N
2 B B SDO
4 C C SDO-N
5 D D 0V SERIAL
6 E E MEASUREMENT
24V BOARD
7 F F

3 G G
H H 0V
9 J J BATSUP
K K BATLD
L L

32
-XS/XP40 Ext. Lamp -433 AWG16 BU
-XS/XP1 0,00 OG -R1.MP
DRIVE MODULE 1 C7 C7

X40 Brake PB -434 AWG16 BU OGWH

4 B16 B8
Brake Release -435 AWG16 BU GYBK
2 B12 C9
Brake Release -436 AWG16 BU GYBU
3 B13 C8
CONTACTOR UNIT
=DM
-X5 0V Brake -438 AWG16 BU GYGN
+A43
4 B14 C10
PTC -439 AWG16 BU OGBU
1 C2 B9
PTC 0V -440 AWG16 BU OGBK
2 C1 B2
0V Brake -437 AWG16 BU OGRD
3 B15 B7

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
-X21 GYRD
LIM 1A
2 D1 B3
LIM 2A GYWH
4 D2 B4
LIM 2B GY
3 D3 C2
LIM 1B OGGN
1 D4 C1

Latest revision: Lab/Office: Status: Plant: = DM

Approved Location: + ORT
EPLAN Sublocation: +
CONTROL CABLE Document no. Rev. Ind Page 5
Next 6
Prepared by, date: Approved by, date: IRB 1400 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

CONTROL MODULE
Customer MANIPULATOR
Connection IRB 1400

AWG 24 OG

-XS/XP5
-XP/XT5
625 -R1.CS
CSA
1 B5
1 A
1
626 CSB
2 C5 B
627 CSC
3 D5 C
628 CSD
4 A6 D
629 CSE
5 B6 E
630 CSF
6 C6 F
631 CSG
7 D6 G
632 CSH
8 A7 H
633 CSJ
9 B7 J
634 CSK
10 C7 K
635 CSL
11 D7 L
636 CSM
12 A8 M

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = CM
Approved Location: + ORT
EPLAN Sublocation: +
CUSTOMER SIGNALS Document no. Rev. Ind Page 6
Next 7
Prepared by, date: Approved by, date: IRB 1400 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

CONTROL MODULE
Customer MANIPULATOR
Connection IRB 1400

-XS/XP8
-XP/XT8
-601 OG
-R1.SW
1 A A
1
-602 OG
2 B B
-603 OG
3 C C
-604 OG
4 D D
-605 OG
5 E E
-606 OG
6 F F
-607 OG
7 J J
-608 OG
8 K K
-609 OG
9 L L
-610 OG
10 M M
-611 OG
11 G G
-612 OG
12 H H

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = CM
Approved Location: + ORT
EPLAN Sublocation: +
POSITION SWITCHES Document no. Rev. Ind Page 7
Next 8
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

SINGLE SERVO DRIVE UNIT

=DM -XS/XP7
-X21 -4000 AWG12 BK
+A41.1.3 U
1 A1
U -4001 AWG12 BK
2 A2
W -4002 AWG12 BK
3 A3
W -4003 AWG12 BK
4 A4
V -4004 AWG12 BK
5 A5
V -4005 AWG12 BK
6 A6

CONTACTOR UNIT
=DM
-X24 -4013 AWG16 BU
+A43 PTC
1 E1
PTC 0V -4014 AWG16 BU
2 E2

3 E3

4 E4

5 E5

6 E6
0V BRAKE -4012 AWG16 BU
F9

F10

F11
-X22 -4006 AWG16 BU
LIM2 ch1
1 F1
LIM2 ch1 ret -4007 AWG16 BU
2 F4
LIM2 ch2 -4008 AWG16 BU
3 F2
LIM2 ch2 ret -4009 AWG16 BU
4 F3

-XS40 EXT. LAMP

1 BRAKE REL. F5
2 BRAKE REL.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
3 BRAKE PB F6

We reserve all rights in this document and in the information contained therein.Reproduction, use or
4 BRAKE REL. +24V -4010 AWG16 BU
5 BRAKE PB BU F7
6 -4011 AWG16
DRIVE MODULE F8
X40 -XP40 -445 AWG16 BU AWG10 GNYE
1
-447 AWG16 BU
2
-448 AWG16 BU
3
-446 AWG16 BU
4

Latest revision: Lab/Office: Status: Plant: = DM

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Next 9
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 9
 1 2 3 4 5 6 7 8

FOR 8 AXIS

SINGLE SERVO DRIVE UNIT

=DM -XS/XP7
-X21 -4000 AWG12
+A41.1.4 U
1 B1
U -4001 AWG12
2 B2
W -4002 AWG12
3 B3
W -4003 AWG12
4 B4
V -4004 AWG12
5 B5
V -4005 AWG12
6 B6

FOR 9 AXIS
SINGLE SERVO DRIVE UNIT
=DM -XS/XP7
-X21 -4000 AWG12
+A41.1.5 U
1 C1
U -4001 AWG12
2 C2
W -4002 AWG12
3 C3
W -4003 AWG12
4 C4
V -4004 AWG12
5 C5
V -4005 AWG12

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
6 C6

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 1 2 3 4 5 6 7 8

EPLAN

The information in this document is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

In no event shall ABB be liable for incidental or consequential damages arising from use of this document
or of the software and hardware described in this document.

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

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

© Copyright 2004 ABB All right reserved.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
ABB Automation Technologies AB

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Robotics
SE-721 68 Västerås
Sweden

Latest revision: Lab/Office: Status: Plant: = DOKUMENTE

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EPLAN Sublocation: +
Title page Document no. Rev. Ind Page 1
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 1 2 3 4 5 6 7 8

EPLAN

Phone :

Customer :
Robot serial number(s) :
Drawing number : 3HAC020538-002_Cables for 140
Drawing version :
Manufacture : 2004-09-23
Type :
Type of installation :
Control cabinet :
Mains voltage :
Supply :
Control voltage :
Year of construction :

Project start : 2004-04-15

Project manager :
Last revision :

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Designed by : jsundin1

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Designed date : 2004-09-23
Number of pages : 8
:

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 1 2 3 4 5 6 7 8

Table of contents DIN_INV_30_1

Plant Location Page Page description Page supplementary field Date Editor
DOKUMENTEDKB 1 Title page Approved 2004-09-09 jsundin1
DOKUMENTEDKB 2 Title page Approved 2004-09-09 jsundin1
DOKUMENTEINV 3 Table of contents: (1 - 8) Approved 2004-09-23 jsundin1
DM ORT 4 SERVO DRIVE SYSTEMIRB 140 Approved 2004-09-23 jsundin1
DM ORT 5 CONTROL CABLEIRB 140 Approved 2004-09-23 jsundin1
CM ORT 6 CUSTOMER SIGNALIRB 140 Approved 2004-09-23 jsundin1
DM ORT 7 EXTERNAL AXIS no 7 Approved 2004-09-23 jsundin1
DM ORT 8 EXTERNAL AXIS no 8-9 Approved 2004-09-23 jsundin1

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We reserve all rights in this document and in the information contained therein.Reproduction, use or
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 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
Latest revision:
1

Prepared by, date:

=DM

0,00
32
+A41.1

-XS/XP1
-X17

-R1.MP1-3

M1R BUGN -400 AWG14 BK

1

13
A1

M1S BURD -402 AWG14 BK

2

17
A3

M1T BUWH -404 AWG14 BK

2

15
A5
MAIN SERVO DRIVE UNIT

M2T BKRD -410 AWG14 BK

4

3
A11

M2S BKGN -408 AWG14 BK

Approved by, date:
5
5

A9

M2R BKBU -406 AWG14 BK

1
6

A7
DC-BUSBAR
3

-R1MP4-6
-X18

M4R BN -418 AWG14 BK

1

6
B3

M4S GNRD -420 AWG14 BK

2

9
B4

M4T GNWH -422 AWG14 BK

3

12
B5

M6T BNBU -432 AWG14 BK

4

3
B11

M6S BNBK -430 AWG14 BK

5

2
4

B10

M6R BU -428 AWG14 BK

6

EPLAN
B9

Lab/Office:
-X19

M3R BKWH -412 AWG14 BK

7
1

A13

M3S BK -414 AWG14 BK

2

11
A15
5

M3T BUBK -416 AWG14 BK

9
3

B1

IRB 140
M5T BNWH -426 AWG14 BK
4

10
B8

M5S BNRD -425 AWG14 BK

7
5

B7
M5R BNGN -424 AWG14 BK
6

4
B6

SERVO DRIVE SYSTEM

AWG10 GNYE
6

AWG10 GNYE

Status:
7

Document no.
Approved
Plant:
Location:
Sublocation: +
MANIPULATOR
DRIVE MODULE

= DM
8

3HAC020538-002 02
+ ORT

Total 8
Next 5
Rev. Ind Page 4
 1 2 3 4 5 6 7 8

AXIS COMPUTER UNIT DRIVE MANIPULATOR

=DM MODULE
+A42

-X4 -XS/XP2 -R1.SMB

SDI
1 A 9 SDI-N
2 B 5 SDO
4 C 8 SDO-N
5 D 4 0V SERIAL
6 E 3 MEASUREMENT
24V BOARD
7 F 7

3 G
H
9 J BATSUP
K 6 BATLD
L 2

32
0,00

-XS/XP40 Ext. Lamp -433 AWG16 BU

-XS/XP1 GYBK
-R1.H1
1 C7 1
Brake PB -434 AWG16 BU GYBU
-R1MP4-6
DRIVE MODULE 4 B16 15

X40 Brake Release -435 AWG16 BU OG

2 B12 8
Brake Release -436 AWG16 BU OGWH
3 B13 5
CONTACTOR UNIT
=DM
-X5 0V Brake -438 AWG16 BU OGRD
+A43
4 B14 13
PTC -439 AWG16 BU OGGN
1 C2 11
PTC 0V -440 AWG16 BU OGBU
-R1.MP1-3
2 C1 2
0V Brake -437 AWG16 BU OGBK
3 B15 14

-X21 GY

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
2 D2 10

We reserve all rights in this document and in the information contained therein.Reproduction, use or
GYWH
4 D1 16
GYRD
3 D3 18
GYGN
1 D4 12

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CONTROL CABLE Document no. Rev. Ind Page 5
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 1 2 3 4 5 6 7 8

CONTROL
MODULE MANIPULATOR
IRB 140

Customer
Connection

AWG 24 OG

-XS/XP5
-XP/XT5
625 -R1.CS
CSA
1 B5 1
626 CSB
2 C5 9
627 CSC
3 D5 2
628 CSD
4 A6 10
629 CSE
5 B6 3
630 CSF
6 C6 11
631 CSG
7 D6 4
632 CSH
8 A7 12
633 CSJ
9 B7 5
634 CSK
10 C7 13
635 CSL
11 D7 6
636 CSM
12 A8 14

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = CM
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CUSTOMER SIGNAL Document no. Rev. Ind Page 6
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 1 2 3 4 5 6 7 8

SINGEL SERVO DRIVE

=DM -XS/XP7
-X21 -4000 AWG12 BK
+A41.1.3 U
1 A1
U -4001 AWG12 BK
2 A2
W -4002 AWG12 BK
3 A3
W -4003 AWG12 BK
4 A4
V -4004 AWG12 BK
5 A5
V -4005 AWG12 BK
6 A6

CONTACTOR UNIT
=DM
-X24 -4013 AWG16 BU
+A43 PTC
1 E1
PTC 0V -4014 AWG16 BU
2 E2

3 E3

4 E4

5 E5

6 E6
0V BRAKE -4012 AWG16 BU
F9

F10

F11
-X22 -4006 AWG16 BU
LIM2 ch1
1 F1
LIM2 ch1 ret -4007 AWG16 BU
2 F4
LIM2 ch2 -4008 AWG16 BU
3 F2
LIM2 ch2 ret -4009 AWG16 BU
4 F3

-XS40 EXT LAMP

1 BRAKE REL. F5
2 BRAKE REL.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
3 BRAKE PB F6

We reserve all rights in this document and in the information contained therein.Reproduction, use or
4 BRAKE REL. +24V -4010 AWG16 BU
5 BRAKE PB -4011 AWG16 BU F7
DRIVE MODULE 6 F8

X40
AWG16 BU
-XP40 -445
1 AWG10 GNYE
-447 AWG16 BU
2
-448 AWG16 BU
3
-446 AWG16 BU
4

Latest revision: Lab/Office: Status: Plant: = DM

Approved Location: + ORT
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EXTERNAL AXIS no 7 Document no. Rev. Ind Page 7
Next 8
Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 8
 1 2 3 4 5 6 7 8

FOR 8 AXIS

SINGLE SERVO DRIVE UNIT

=DM -XS/XP7
-X21 -4000 AWG12
+A41.1.4 U
1 B1
U -4001 AWG12
2 B2
W -4002 AWG12
3 B3
W -4003 AWG12
4 B4
V -4004 AWG12
5 B5
V -4005 AWG12
6 B6

FOR 9 AXIS
SINGLE SERVO DRIVE UNIT
=DM -XS/XP7
-X21 -4000 AWG12
+A41.1.5 U
1 C1
U -4001 AWG12
2 C2
W -4002 AWG12
3 C3
W -4003 AWG12
4 C4
V -4004 AWG12
5 C5
V -4005 AWG12

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
6 C6

We reserve all rights in this document and in the information contained therein.Reproduction, use or
Latest revision: Lab/Office: Status: Plant: = DM
Approved Location: + ORT
EPLAN Sublocation: +
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Prepared by, date: Approved by, date: 3HAC020538-002 02 Total 8
 3HAC021313-001 (part 2 of 2), rev A, en


ABB Automation Technology Products AB
Robotics
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592