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Table of contents
Overview of this manual ................................................................................................................... 7
Safety ................................................................................................................................................ 8
3 Maintenance 29
3.1 Maintenance schedule ....................................................................................... 29
3.2 Changing/replacing activities ............................................................................... 30
3.3 Cleaning activities ............................................................................................. 31
4 Decommission 33
4.1 Introduction ...................................................................................................... 33
4.2 Environmental information .................................................................................. 34
5 Reference information 35
5.1 Introduction ...................................................................................................... 35
6 Circuit diagram 37
6.1 About circuit diagram ......................................................................................... 37
Index 39
Prerequisites
A maintenance/repair/installation craftsman working with an ABB manipulator
must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
References
Reference Document ID
Operating manual - Emergency safety information 3HAC027098-001
Same document num-
ber regardless of lan-
guage.
Operating manual - General safety information 3HAC031045-001
Product manual - Robot controller S4C+ M2000 3HAC021333-001
Product manual - Robot controller S4C+ Automotive M2000A 3HAC022419-001
Product Specification - Paint automation S4P Robot Controller 3HNT 01000-1
Product Specification - Paint automation S4P+ Robot Controller 3HNT 00016-1
Safety manual 3HNT 00071-1
Operating manual-General safety information for S4C and S4Cplus 3HAC044215-001
Revisions
Revision Description
- First edition
A Add the installation procedure.
Add the information of adapter harness.
Delete some types of drive unit in S4C/S4C+ and S4P/S4P+ controller which
can be replaced by the universal drive unit.
Safety
Voltage related risks
A danger of high voltage is associated with, for example, the following parts:
• Be aware of stored electrical energy (DC link) in the controller.
• Units such as I/O modules, can be supplied with power from an external
source.
• The mains supply/mains switch
• The power unit
• The control power supply
• The rectifier unit (262/430 VAC and 400/800 VDC. Note: Capacitors!)
• The drive unit (400/800 VDC)
• The service outlets (115/230 VAC)
• The power supply unit for additional tools, or special power supply units for
the machining process.
• The external voltage connected to the control cabinet remains live even when
the robot is disconnected from the mains.
• Additional connections.
Safety regulations
Before beginning mechanical and/or electrical installations, make sure you are
familiar with the safety regulations described in the manual:
• For S4C/S4C+ controller, see Operating manual - General safety information
for S4C and S4Cplus.
•
• For S4P/S4P+ controller, see Safety manual in References on page 7.
Overview
The Universal drive aims to replace the drive unit in S4C/S4C+ and S4P/S4P+
controller with four types of universal drive unit.
The drive unit in S4C/S4C+ and S4P/S4P+ controller can be grouped into two
categories:
• Rectifier unit
• Drive unit
The main function of rectifier unit is to rectify 3 phase AC voltage into DC voltage.
The main function of drive unit is to regulate the servo motor current in manipulator.
This manual covers four types of universal drive unit which can replace six types
of drive unit in S4C/S4C+ and S4P/S4P+ controller. Table below shows the
replacement conception.
S4C/S4C+ and S4C/S4C+ Universal drive Universal Description Adapter harness
S4P/S4P+ and article number drive HW
Drive article S4P/S4P+ ID
number Drive HW ID
3HAC053996-001
3HAB8101-3 DSQC345C
3HAC053997-001
3HAC048012-001 DSQC440 LV rectifier
3HAB8101-14 DSQC345E 3HAC053996-001
3HAC053997-001
3HAB8101-19 DSQC545A 3HAC048013-001 DSQC441 HV rectifier Not applicable
3HAB8101-7 DSQC346C 3HAC048014-001 DSQC442 Drive 3pack Not applicable
3HAB8101-13 DSQC346U 3HAC048015-001 DSQC443 Drive 2pack 3HAC053998-001
3HAB8101-18 DSQC546A Not applicable
1.2 Specification
General specification
Operating environments
All universal drive units have to withstand the following environmental requirements.
Parameter Value
Altitude, operating, IEC 61131-2 (no test required) 100 Kpa to 84 Kpa
Altitude, transportation, IEC 61131-2 (no test required) 100 Kpa to 70 Kpa
i Ambient temperature inside the cabinet. Components shall be selected to withstand this temperature.
ii Temperature of ambient air outside the cabinet. This is the temperature of the air that can be used
to cool heat sink fins. If forced airflow is required, necessary flow shall be stated.
iii This is an optional ambient temperature of air outside the cabinet. If forced airflow is required,
necessary flow shall be stated. Note that this is not an optional requirement for the Drive Units. It
is an optional system configuration meaning the cooling can be different between the two stated
ambient temperatures.
Rectifier specification
UDC Output voltage of DC-bus ii 280 VDC to 453 VDC 511 VDC to 825 VDC
xx1500000667
Item Description
A Rectifier
B Bus bar
C Drive unit
D Bracket
xx1500000681
Item Description
A DIP switch
B Sheet area for label
C Terminal
D Terminal for bus bar
E Groove for assembly
Dimension
The five types of universal drive unit has the same external dimension as show in
follow.
xx1500000666
Procedure
The following procedure provides information about how to remove and refit the
rectifier or the drive unit in S4C/S4C+ controller.
The replacement procedure for the S4P/S4P+ controller are similar with the
procedures for the S4C/S4C+ controller.
Action Description
1 Switch off the main power on the controller
cabinet.
Note
S4Cplus cont
WARNING
xx1500000671
xx1500000669
Action Description
4 Move the locking spring to release the rectifier
unit (or drive unit).
xx1500000670
xx1500000672
xx1500000668
xx1500000674
Action Description
9 Reconnect all the connectors.
Note
xx1500000673
Connector layout
The following provides information for connecting the Universal drive unit to the
control cabinet and manipulator.
The Universal drive unit have the same simple plug and installation procedure as
S4C/S4C+ and S4P/S4P+ drive unit.
LV rectifier
xx1500000663
HV rectifier
xx1500000663
Drive 3pack
xx1500000664
Drive 2pack
xx1500000665
Cable harness
For the S4C/S4C+ and the S4P/S4P+ controller which has drive 2pack drive unit
and LV rectifier , adapter is needed as shown below.
xx1500000680
Item Description
A LV rectifier
B 3HAC053997-001
C 3HAC053996-001
D Drive 2pack
E 3HAC053998-001
General
The universal driver unit uses 4 bits, 16 options DIP switch to configure the different
types of drive unit in S4C/S4C+ and S4P/S4P+ controller.
Procedure
Action Description
1 Set the DIP switch SW1 on the drive unit to
be 0b1111 (status:↑↑↑↑) before powering
on the drive unit.
xx1500000675
xx1500000676
xx1500000684
Action Description
4 Start the TFTP client on PC.
Start the tftpd32.exe and do following opera-
tion:
• Select Tftp Client
• Server Interface: select 192.168.1.20
• Host: 192.168.1.10
• Port : default 69
• Local File: Browse to the path of im-
age
• Block Size: 512
xx1500000677
xx1500000678
xx1500000679
xx1500000682
Action Description
8 If the power is off or the network is broken
during the upgrade process, restart the pro-
cedure.
xx1500000683
3 Maintenance
3.1 Maintenance schedule
General
The Universal drive unit must be maintained at regular intervals to ensure its
function. The maintenance activities and their respective intervals is in accordance
with the controller which is equipped with the drive unit.
Intervals
Activities
For the changing or replacing of universal drive unit please see Installation of
universal drive unit on page 15
Required equipment
Internal cleaning
Clean the cabinet interior with an ESD protected vacuum cleaner, if necessary.
4 Decommission
4.1 Introduction
Introduction
This section contains information to consider when taking a product, robot or
controller, out of operation.
It deals with how to handle potentially dangerous components and potentially
hazardous materials.
General
All used grease/oils and dead batteries must be disposed of in accordance with
the current legislation of the country in which the robot and the control unit are
installed.
If the robot or the control unit is partially or completely disposed of, the various
parts must be grouped together according to their nature (which is all iron together
and all plastic together), and disposed of accordingly. These parts must also be
disposed of in accordance with the current legislation of the country in which the
robot and control unit are installed.
Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly to prevent health or environmental hazards.
Material Example application
Copper Main computer
Steel Cables
Stainless steel Cabinet structure, plates, screws, etc.
Plastic/rubber Cables, connectors, etc.
Aluminium Hear sink on power supplies and drive units
Lead Electronics
Brominated flame retardants Electronics
5 Reference information
5.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.
6 Circuit diagram
6.1 About circuit diagram
Overview
The circuit diagrams are not included in this manual. Reuse the S4C/S4C+ and
S4P/S4P+ controller circuit diagram for connection.
Product Article numbers for circuit diagrams
Circuit diagram - Control system M2000 3HAC5582-2
Circuit diagram - Control system M98 3HAC2393-3
Circuit diagram - IRB 580-13 - S4P+ 3HNA013768-001
Circuit diagram - IRB 5500 - S4P+ with CBS 3HNA013835-001
Circuit diagram - IRB 5400-1X/2X - S4P+ incl. 3HNA014315-001
CBS
Circuit diagram - IRB 540-12 - S4P+ w/MCOB 3HNA014427-001
Circuit diagram - IRB 5300 - S4P+ 3HNA014402-001
Circuit diagram - S4P 3HNE 02294-1
Index P
plastic
disposal, 34
A
aluminum R
disposal, 34 rubber
disposal, 34
B
brominated flame retardants S
disposal, 34 stainless steel
disposal, 34
L steel
lead
disposal, 34
disposal, 34
3HAC047989-001, Rev A, en
ABB AB
Discrete Automation and Motion
Robotics
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400
www.abb.com/robotics