ABB 500 ABB IRC5 Series Electrical Maintenance and Troubleshooting
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Phone: 248-484-5500
BUS_Training@bizlinktech.com
Course Information
- Code ID: ABB 500 IRC5
- Course Type: Instructor led, taught with a 40/60 theory to hands-on approach. Theory portions will be followed by lab exercises to ensure an in-depth understanding of all key topics
- Course Length: 5 days
- Student Profile: Maintenance Technicians, Skilled Trades, Engineers, Supervisory Staff
- Prerequisites: ABB 300 Operational Troubleshooting and Programming
Course Profile
This 5-day core program is designed to prepare each student with the skills necessary to safely troubleshoot and electrically repair the ABB IRC5 robot controller and manipulator. This class takes a system approach, covering not only the robot controller, but also the manipulator, local I/O on the robot, and remote I/O to the cell controller. This course focuses on ABB’s Design 04, 06, 09, and 14 IRC5 robot systems. In order to minimize plant floor downtime, this course focuses on components that exhibit high incidents of faults and failure.
Topics Covered
BizLink Robotic Solutions USA, Inc. offers flexibility in training curriculum. Please ask the instructor for any system-specific information relating to specific applications.
- Safety precautions when electrically troubleshooting and replacing components
- Overview of robot system components, including controller and manipulator
- Identification and function of controller components, including common revisions (Design 04, 06, 09, and 14)
- Identification and function of manipulator components, including common versions (1600, 6600, 7600, etc.)
- Interpreting error and fault messages, codes, and status LEDs for effective diagnoses of problems
- Use of circuit diagrams to aid in setup and troubleshooting of the robot system
- Troubleshooting power distribution (transformer, circuit protection, power supplies, and energy bank)
- Troubleshooting the computer system (main computer, axis computer, SafeMove board, and storage media)
- Troubleshooting the safety circuit (panel board, contactor board, power contactors, and safety I/O signals)
- Troubleshooting the motion control (servo) system components (rectifier, drive unit, capacitor unit, bleeder resistor, serial measurement board, resolvers, and motors)
- Controller component removal and replacement
- Serial measurement board batteries
- Motor changeout and recovery
- Configuring and troubleshooting I/O connections
Course Objectives
Upon successful completion of this course, participants will be able to demonstrate the ability to:
- Identify and describe the functions of all components of the ABB IRC5 robot system.
- Trace power and signal connections using the ABB controller an manipulator circuit diagrams.
- Utilize fault messages and LED indicators to determine which components they are associated with.
- Troubleshoot and solve failures associated with the power distribution system.
- Troubleshoot and solve failures associated with the computer system.
- Troubleshoot and solve failures associated with the safety circuit.
- Troubleshoot and solve failures associated with the motion control system.
- Remove and replace robot controller components.
- Remove and replace manipulator motors in different scenarios.
- Remove and replace serial measurement board batteries with limited downtime.
- Interpret and troubleshoot end-effector and tooling I/O.
- Interpret and troubleshoot PLC communications (DeviceNet, EtherNet/IP, etc.).
- Interpret and troubleshoot I/O signals associated with SafeMove.
- Create and restore robot system backups.