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ABB 3HAC5687-1 Connection Unit 

1. Key Parameters

• Order Code/Part Number: 3HAC5687-1 (unique identifier for procurement and compatibility with ABB robotic systems)
• Core Function: Centralized connection hub for power, signal, and communication links between IRC5 controller, robot joints, and external devices
• Target System Compatibility: ABB IRC5 robot controller series (for 6-axis industrial robots, collaborative robots, and SCARA robots)
• Connection Types & Quantity:
  • Power Connections: 2× 3-phase AC input terminals (for robot joint power, 400V AC, 50/60Hz); 4× 24V DC terminals (for low-voltage I/O power)
  • Signal Connections: 24× digital I/O terminals (24V DC, compatible with sinking/sourcing devices); 8× analog signal terminals (0~10V DC / 4~20mA, 12-bit resolution)
  • Communication Connections: 2× Ethernet ports (Profinet IRT, for controller-robot synchronization); 1× RS-485 port (Modbus RTU, for external device communication); 1× ABB proprietary robot bus port (for joint module data exchange)
• Electrical Ratings:
  • Maximum AC Power Current: 15A (per 3-phase input)
  • Maximum DC I/O Current: 2A per terminal, 8A total (24V DC)
  • Insulation Voltage (Ui): 690V AC (between power and signal circuits)
  • Impulse Withstand Voltage (Uimp): 8kV
• Mechanical Specifications:
  • Dimensions (W×H×D): 180mm × 220mm × 60mm (compact design for IRC5 cabinet integration)
  • Mounting Method: Chassis mounting (dedicated slot in IRC5 controller enclosure; secured via M4 screws)
  • Terminal Type: Screw terminals (for secure wiring; compatible with 0.5mm²~2.5mm² copper conductors)
• Environmental Ratings:
  • Operating Temperature Range: 0℃~+50℃ (32℉~122℉)
  • Storage Temperature Range: -20℃~+70℃ (-4℉~158℉)
  • Humidity Tolerance: ≤90% RH (non-condensing)
  • Vibration Resistance: 10~2000Hz, 3g acceleration (compliant with IEC 60068-2-6)
• Compliance Standards: IEC 61010-1 (safety for electrical equipment), IEC 61000-6-2 (EMC immunity), UL 508 (industrial control equipment)

2. Product Features

• Centralized Connection Hub: Consolidates power, signal, and communication links into a single unit—reducing wiring clutter in the IRC5 cabinet and simplifying system installation/commissioning.
• High-Speed Communication Support: Integrates Profinet IRT ports for sub-millisecond synchronization between the IRC5 controller and robot joints, ensuring precise motion control (e.g., ±0.02mm path accuracy for 6-axis robots).
• Robust Electrical Isolation: 690V AC insulation between power and signal circuits eliminates ground loops and cross-interference from high-voltage robot joint power, protecting sensitive I/O signals and communication links.
• Secure Terminal Design: Screw terminals with captive screws ensure reliable wire connections (preventing loosening from vibration) and accommodate a wide range of conductor sizes (0.5mm²~2.5mm²), adapting to diverse wiring needs.
• Plug-and-Play Compatibility: Pre-configured for ABB IRC5 systems—no additional software setup required for basic functionality; automatically recognized by the controller’s diagnostic tools for quick fault detection.
• Industrial Durability: Flame-retardant plastic housing (UL94 V-0 rating) and EMI shielding withstand harsh manufacturing environments (dust, oil mist, electrical noise), ensuring long-term reliability in automotive, electronics, or metalworking plants.
• Easy Maintenance: Clear terminal labeling and color-coded wiring guides simplify troubleshooting and replacement; the unit can be removed from the IRC5 cabinet without disconnecting all external wires (via quick-release chassis locks).

3. Application Fields

• Automotive Manufacturing: Facilitates connections between IRC5 controllers and 6-axis robots for welding, painting, or component assembly—ensuring stable power/signal transmission for high-volume, precision tasks.
• Electronics Assembly: Links SCARA robots or collaborative robots to vision systems, grippers, and PCB handling equipment—supporting synchronized motion for delicate operations (e.g., chip placement, soldering).
• Food & Beverage Processing: Integrates with hygienic robots (IP67-rated) to connect sensors (e.g., product detection) and actuators (e.g., grippers)—complying with food safety standards and enabling contactless product handling.
• Aerospace & Defense: Connects precision robots for aircraft component machining (e.g., titanium parts) and composite layup—ensuring reliable communication between the controller and high-torque robot joints.
• Logistics & Material Handling: Links robotic arms (for order picking, palletizing) to conveyor sensors and warehouse management systems (WMS)—supporting real-time data exchange for efficient inventory flow.

4. Precautions

• System Compatibility: Use exclusively with ABB IRC5 robot controllers—non-compatible systems will cause communication failures or electrical mismatches, risking damage to the connection unit or connected devices.
• Wiring Safety:
  • Follow ABB’s wiring diagrams to match terminal functions (power/signal/communication); incorrect wiring (e.g., connecting AC power to signal terminals) will destroy internal circuits.
  • Torque terminal screws to 0.8N·m~1.2N·m (per ABB specifications) to avoid loose connections (which cause overheating) or wire damage.
• Power Supply Matching: Ensure the 3-phase AC input (400V AC) and 24V DC I/O power match the IRC5 controller’s output ratings—overvoltage will trigger internal fuses and disable the unit.
• EMI Mitigation: Use shielded twisted-pair cables for Ethernet and RS-485 connections; ground cable shields at the controller end (single-point grounding) to minimize interference from robot motors or nearby high-power equipment.
• Environmental Limits: Do not operate in environments exceeding 50℃ or 90% RH (condensing); install the IRC5 cabinet in a ventilated area and avoid exposure to corrosive gases (e.g., sulfur, coolant vapors) to prevent terminal corrosion.
• Maintenance Safety: Disconnect the IRC5 controller’s main power before servicing the unit—capacitors in the power circuit may retain charge for up to 5 minutes, posing electric shock risks. Use a multimeter to verify no voltage before wiring adjustments

The structure and details of the product：

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