Universal Drive Unit 3HAC047989-en PDF

Product manual
Universal drive unit

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Workspace Main version a173 (not checked in)
Published 2016-08-24 at 08:52:28
Skribenta version 4.6.318
Product manual
Universal drive unit
Document ID: 3HAC047989-001
Revision: A
© Copyright 2015-2016 ABB. All rights reserved.

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.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.

ABB Engineering (Shanghai) Ltd.
No.4528, KangXin Highway, PuDong New District,
SHANGHAI 201319
CHINA
Table of contents
Table of contents
Overview of this manual ................................................................................................................... 7
Safety ................................................................................................................................................ 8
1 Introduction to the Universal drive unit 9

1.1 Overview ......................................................................................................... 9
1.2 Specification .................................................................................................... 10
2 Installation and commissioning 13

2.1 Overview ......................................................................................................... 13
2.2 Installation of universal drive unit ......................................................................... 15
2.3 Electrical connections ........................................................................................ 19
2.4 Configuration of universal drive unit ..................................................................... 24
2.5 Firmware upgrade ............................................................................................. 25
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
Product manual - Universal drive unit 5

3HAC047989-001 Revision: A
This page is intentionally left blank
Overview of this manual
Overview of this manual

Content of this manual
This manual provides information on function, installation and maintenance of the
Universal drive unit.
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
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.
8 Product manual - Universal drive unit

1 Introduction to the Universal drive unit
1.1 Overview

1.1 Overview
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
The Universal drive unit has the following features:

• No cabling and connector changing in controller.
• When LV rectifier and Drive 2pack are used to replace the S4C drive, adapter
harness will be required to connect the drive connector and controller harness
connector.
• Same BUS bar connection.
• No RobotWare change.
• Sheet metal hood will be used to replace plastic hood.
• Machining heat sink will replace die casting.
• Same installation dimension and mounting method with S4C/S4C+ and
S4P/S4P+ drive unit.
• Same quality and protection level.

1.2 Specification
1.2 Specification
General specification
Specification LV rectifier HV rectifier Drive 3pack Drive 2pack

Weight 4.94 kg 5.08 kg 4.26 kg 4.23 kg
Color Sheet metal ori- Sheet metal ori- Sheet metal ori- Sheet metal ori-
ginal color ginal color ginal color ginal color
IP degree IP 20 IP 20 IP 20 IP 20
Ambient temper- -25° C to 65° C -25° C to 65° C -25° C to 65° C -25° C to 65° C
ature
Storage temperat- -40° C to 70° C -40° C to 70° C -40° C to 70° C -40° C to 70° C
ure
Relative humidity 10% to 95% 10% to 95% 10% to 95% 10% to 95%
Operating environments
All universal drive units have to withstand the following environmental requirements.
Parameter Value
Operating temperature inside cabinet i +5° C to +65° C
Operating temperature outside cabinet ii +5° C to +45° C
Optional temperature outside cabinet iii +5° C to +52° C
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
Parameter LV rectifier HV rectifier

Unit Input voltage (phase-to-phase) 262 Vrms, (-15% to +10%) 475 Vrms, ( -15% to +10%)
Input voltage frequency 48.5 Hz to 61.8 Hz 48.5 Hz to 61.8 Hz
Inrush current (at start-up) i 250 Apeak 250 Apeak
Charge time to stable DC-bus 0.5 s 0.5 s

Time of peak output current 3s 3s
UDC Output voltage of DC-bus ii 280 VDC to 453 VDC 511 VDC to 825 VDC
Discharge time to <48 VDC iii ≤1s ≤1s
Continuous DC current 23 A, norm. 27 A, norm.

Peak current ≤ 95 A ≤ 93 A
i This is the total inrush current of both the main drive unit and up to 3 additional axes (since this is
primarily affecting the input fuses and transformer).
Continues on next page

1.2 Specification
Continued
ii Minimum output voltage is calculated according to:

Maximum output voltage is maximum permissible DC-bus voltage which shall not be exceeded to
prevent the permanent damage of motors, cables, rectifier or drive units.
iii Discharge time of DC-bus at loss of logic power. According to EN 60204-1.
Inverter nodes specification
Parameter Note/Illustration Drive 3pack Drive 2pack i

Input voltage min. 280 VDC 280 VDC
norm. 380 VDC 380/670 VDC
max. 450 VDC 800 VDC
Output current Node 0 19 Arms 29.7 Arms@ 380
VDC
24.3 Arms@ 670
VDC
Node 1 11.3 Arms 55 Arms@ 380
VDC
51 Arms@ 670
VDC
Node 2 6.7 Arms Not applicable
Motor de-rating ratio ii max. 1:8 1:8
Switch frequency (kHz) norm. 4 kHz 4 kHz

Electric frequency (Hz) min. 0 Hz 0 Hz
max. 500 Hz 500 Hz
Time for peak current during max. 3s 3s
acceleration (s)
Time for peak current at zero max. 3s 3s
speed (s)
i Drive 2pack DSQC443 can be used in low voltage (262 Vac) controller and high voltage (475 Vac)
controller.
ii This is the maximum ratio of drive max current to motor max current. This allows smaller motors
to be used with larger drives and puts some requirements on current measurement.

2 Installation and commissioning
2.1 Overview

2.1 Overview
Overview of drive unit inside S4C/S4C+ and S4P/S4P+ controller

Following figure shows the overview of drive unit installed in robot controller. There
are totally four units including one rectifier unit and three drive units.
The rectifier unit and drive unit have the same dimension with different connector
position.
xx1500000667
Item Description
A Rectifier
B Bus bar
C Drive unit
D Bracket

2.1 Overview
Continued
Overview of universal drive unit
xx1500000681
Item Description
A DIP switch
B Sheet area for label
C Terminal
D Terminal for bus bar
E Groove for assembly

2.2 Installation of universal drive unit
Dimension
The five types of universal drive unit has the same external dimension as show in
follow.
xx1500000666

Continued
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
Location of the main switch on both S4C and

S4C+ controllers are the same.
S4Cplus cont
A: Main power switch

2 Use a wrist strap.
WARNING
The unit is sensitive to ESD and will be des-

troyed if subjected to it! Before handling, make
sure you are connected to earth through a
special ESD wrist bracelet or similar.
xx1500000671
3 Swing the power supply to access the rectifier

unit (or drive unit), remove the bar and discon-
nect any connectors.
xx1500000669

Continued
Action Description
4 Move the locking spring to release the rectifier
unit (or drive unit).
xx1500000670
5 Pull the rectifier unit (or drive unit) out.
xx1500000672
6 Configure the DIP switch of rectifier unit (or

drive unit).
For how to configure the DIP switch see Uni-
versal drive unit configuration on page 24.
xx1500000668
7 Align the groove on the bottom plate of drive

unit with the fixture in controller bracket plate
show in figure.
xx1500000674
A: Groove on drive unit

B: Locking spring
C: Fixture on controller bracket plate
8 Press the locking spring to refit the rectifier
unit (or drive unit).

Continued
Action Description
9 Reconnect all the connectors.
Note
Some drive unit need adapter cable, for the

detail of connectors and cable see Electrical
connections on page 19.
10 Refit the bar power supply bar.
xx1500000673
11 Switch on the power on the controller cabinet.

2.3 Electrical connections
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
Item Port Description

A X1 Logic port including RS422 and 15V power supply
B Service Ethernet port only for upgrade
C X4 Not applicable
D Bus bar Bus bar port
E X3 Bleeder
F X2 Main power

Continued
HV rectifier
xx1500000663

C X4 Not applicable
E X3 Bleeder
F X2 Main power

Continued
Drive 3pack
xx1500000664

C Bus bar Bus bar port
D X2 Motor

Continued
Drive 2pack
xx1500000665

C X3 Motor
E X2 Power motor
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

Continued
Item Description
A LV rectifier
B 3HAC053997-001
C 3HAC053996-001
D Drive 2pack
E 3HAC053998-001
The detail information is as follow.

S4C/S4C+ and Universal drive art- Description Adapter harness
S4P/S4P+ Drive article number
icle number
3HAB8101-3 3HAC053996-001
3HAC053997-001
3HAC048012-001 LV rectifier
3HAB8101-14 3HAC053996-001
3HAC053997-001
3HAB8101-19 3HAC048013-001 HV rectifier Not applicable
3HAB8101-7 3HAC048014-001 Drive 3pack Not applicable
3HAB8101-13 3HAC048015-001 Drive 2pack 3HAC053998-001
3HAB8101-18 Not applicable

2.4 Configuration of universal drive unit
2.4 Configuration of universal drive unit
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.
Universal drive unit configuration

Universal drive unit can be configured with standard PC software to map the
universal drive unit module type to S4C/S4C+ and S4P/S4P+ module type.
S4C/S4C+ and Universal drive art- Description DIP switch status i
S4P/S4P+ Drive article number
icle number 1 2 3 4
3HAB8101-3 3HAC048012-001 LV rectifier 0x2 ↓ ↑ ↓ ↓
3HAB8101-14 0x4 ↓ ↓ ↑ ↓
3HAB8101-19 3HAC048013-001 HV rectifier 0x9 ↑ ↓ ↓ ↑
3HAB8101-7 3HAC048014-001 Drive 3pack ii 0x2 ↓ ↑ ↓ ↓
3HAB8101-13 3HAC048015-001 Drive 2pack iii 0x1 ↑ ↓ ↓ ↓

3HAB8101-18 0x2 ↓ ↑ ↓ ↓
i State 0xF is reserved for firmware upgrade. Firmware upgrade on page 25.
ii If inverter nodes on Drive 3pack DSQC442 are partly used, the bit 4&3 shall be configured as the
node number to be removed. See table below:
Actual node NR Removed node NR Bit 4 Bit 3

3 0 0 (↓) 0 (↓)
2 1 0 (↓) 1 (↑)
1 2 1 (↑) 0 (↓)
iii If inverter nodes on Drive 2pack DSQC443 are partly used, the bit 4&3 shall be configured as the
node number to be removed. See table below:
Actual node NR Removed node NR Bit 4 Bit 3

2 0 0 (↓) 0 (↓)
1 1 0 (↓) 1 (↑)

2.5 Firmware upgrade
Procedure
Action Description
1 Set the DIP switch SW1 on the drive unit to
be 0b1111 (status:↑↑↑↑) before powering
on the drive unit.
xx1500000675
2 Connect the drive unit to the PC with TFTP

client has been installed.
xx1500000676
3 Confirm the firewall and IP settings on the

PC side. Note
• Disable our McAfee Host Intrusion
Prevention (Which will block TFTP Remember to enable it when connect with
communication between PC and Hand, Internet
seek help from IS department)
• Set IP address of your PC:
192.168.1.20
xx1500000684

Continued
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
5 Upgrade the Firmware to the drive unit

through the TFTP client.
• Click the Put button on tftpd32
xx1500000678
6 Waiting for the complete of the process.
xx1500000679
7 The firmware upgrade is done and pop-up

the window: 0 block retransmitted.
xx1500000682

Continued
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
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
Equipment Maintenance Interval Note/Illustration

activity
Universal drive unit general mainten- 12 months i
ance
Cables/connectors Inspection 12 months Check that the cables/connectors
are not damaged.
Power source Cleaning when needed
i The time interval is in accordance with the controller which is equipped with the drive unit.

3 Maintenance
3.2 Changing/replacing activities
3.2 Changing/replacing activities
Activities
For the changing or replacing of universal drive unit please see Installation of
universal drive unit on page 15

3 Maintenance
3.3 Cleaning activities
3.3 Cleaning activities
Required equipment
Equipment, etc. Note

Vacuum cleaner ESD protected
Internal cleaning
Clean the cabinet interior with an ESD protected vacuum cleaner, if necessary.
Do's and don'ts!

The section below specifies some special considerations when cleaning the
controller.
Always:
• use ESD Protection
• use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
• check that all protective covers are fitted to the controller before cleaning!
Never:
• remove any covers or other protective devices when cleaning the outside of
the controller!
• use compressed air or spray with a high pressure cleaner!
• leave the door open when cleaning exterior

4 Decommission
4.1 Introduction
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.

4 Decommission
4.2 Environmental information
4.2 Environmental information
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
5 Reference information
5.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.
Applicable safety standards

Safety standards
The robot conforms to the following standards:
• EN 292-1 - Safety of machinery, terminology
• EN 292-2 - Safety of machinery, technical specifications
• EN 954-1 - Safety of machinery, safety related parts of control systems
• EN 60204 - Electrical equipment of industrial machines
• IEC 204-1 - Electrical equipment of industrial machines
• ISO 10218, EN 775 - Manipulating industrial robots, safety
• ANSI/RIA 15.06/1999 - Industrial robots, safety requirements
• ISO 9787 - Manipulating industrial robots, coordinate systems and motions
• IEC 529 - Degrees of protection provided by enclosures
• EN 50081-2 - EMC, Generic emission
• EN 61000-6-2 - EMC, Generic immunity
• ANSI/UL 1740-1998 (option) - Standard for Industrial Robots and Robotic
Equipment
• CAN/CSA Z 434-94 (option) - Industrial Robots and Robot Systems - General
Safety Requirement
The robot complies fully with the health and safety standards specified in the EEC’s
Machinery Directives.

6 Circuit diagram
6.1 About circuit diagram
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
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

Contact us
3HAC047989-001, Rev A, en
ABB AB
Discrete Automation and Motion
Robotics
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400
ABB AS, Robotics

Discrete Automation and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 51489000
ABB Engineering (Shanghai) Ltd.

No. 4528 Kangxin Highway
PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
www.abb.com/robotics

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Product manual

Universal drive unit

© Copyright 2015-2016 ABB. All rights reserved.

© Copyright 2015-2016 ABB. All rights reserved.

1 Introduction to the Universal drive unit 9

2 Installation and commissioning 13

Product manual - Universal drive unit 5

Overview of this manual

Product manual - Universal drive unit 7

8 Product manual - Universal drive unit

1 Introduction to the Universal drive unit

The Universal drive unit has the following features:

Product manual - Universal drive unit 9

Specification LV rectifier HV rectifier Drive 3pack Drive 2pack

Operating temperature inside cabinet i +5° C to +65° C

Operating temperature outside cabinet ii +5° C to +45° C

Optional temperature outside cabinet iii +5° C to +52° C

Parameter LV rectifier HV rectifier

Inrush current (at start-up) i 250 Apeak 250 Apeak

Charge time to stable DC-bus 0.5 s 0.5 s

Discharge time to <48 VDC iii ≤1s ≤1s

Continuous DC current 23 A, norm. 27 A, norm.

Continues on next page

ii Minimum output voltage is calculated according to:

Inverter nodes specification

Parameter Note/Illustration Drive 3pack Drive 2pack i

Motor de-rating ratio ii max. 1:8 1:8

Switch frequency (kHz) norm. 4 kHz 4 kHz

Product manual - Universal drive unit 11

2 Installation and commissioning

Overview of drive unit inside S4C/S4C+ and S4P/S4P+ controller

Continues on next page

Overview of universal drive unit

14 Product manual - Universal drive unit

2.2 Installation of universal drive unit

Continues on next page

Location of the main switch on both S4C and

A: Main power switch

The unit is sensitive to ESD and will be des-

3 Swing the power supply to access the rectifier

Continues on next page

5 Pull the rectifier unit (or drive unit) out.

6 Configure the DIP switch of rectifier unit (or

7 Align the groove on the bottom plate of drive

A: Groove on drive unit

Continues on next page

Some drive unit need adapter cable, for the

10 Refit the bar power supply bar.

11 Switch on the power on the controller cabinet.

18 Product manual - Universal drive unit

2.3 Electrical connections

Item Port Description

Continues on next page

Item Port Description

Continues on next page

Item Port Description

Continues on next page

Item Port Description

Continues on next page

The detail information is as follow.

Product manual - Universal drive unit 23

2.4 Configuration of universal drive unit

Universal drive unit configuration