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ABB DSQC505 Power Supply Module  

1. Key Parameters

• Product Model: DSQC505
• Order Code Reference: Typically paired with IRC5 controller part numbers (e.g., 3HAC028357-001) for procurement
• Product Series: ABB IRC5 Robot Controller Power Supply Modules
• Core Function: Converts AC mains power to regulated DC voltages for IRC5 controller components; provides stable power to robot drives, logic circuits, and safety systems; protects against power surges and voltage fluctuations
• Electrical Input Specifications:
  • Input Voltage Range: 100V~240V AC (universal input; compatible with global power grids)
  • Input Frequency: 50Hz~60Hz (auto-adaptive to regional power standards)
  • Input Current: 8A (max at 100V AC); 4A (max at 240V AC)
  • Input Protection: Overcurrent protection (10A circuit breaker); surge protection (IEC 61000-4-5: ±2kV contact discharge, ±4kV air discharge)
• DC Output Specifications:
  • Output Channels (Regulated):
    • +5V DC / 10A: Powers IRC5 controller logic circuits, CPU, and memory modules
    • +24V DC / 5A: Supplies power to robot safety systems, I/O modules (e.g., DSQC651), and auxiliary sensors
    • +15V DC / 2A: Powers robot encoder circuits and drive reference signals
    • -15V DC / 2A: Complements +15V DC for encoder and drive circuits (balanced power)
  • Output Voltage Regulation: ±1% (max deviation from nominal voltage; ensures stable operation of sensitive electronics)
  • Output Ripple & Noise: ≤50mVpp (for +5V/+24V); ≤100mVpp (for ±15V); minimizes electrical interference with robot sensors
  • Output Protection: Overvoltage protection (OVP), overcurrent protection (OCP), and short-circuit protection (SCP) for each channel
• Mechanical Specifications:
  • Housing Type: Metal-reinforced flame-retardant plastic (UL94 V-0; provides EMI shielding and mechanical robustness)
  • Dimensions (W×H×D): 180mm × 120mm × 80mm (custom form factor; fits precisely in IRC5 controller chassis)
  • Mounting: Chassis-mounted (screw-in installation; aligns with IRC5 controller’s internal power compartment)
  • Weight: Approximately 1.2kg
  • Connector Type: ABB proprietary multi-pin connector (keyed design; prevents reverse insertion and ensures secure mating with IRC5 backplane)
  • LED Indicators (on front panel):
    • Power Input (AC): Green (AC power present); Off (no AC input or input fault)
    • DC Outputs (+5V/+24V/±15V): Green (corresponding DC voltage normal); Red (output fault, e.g., overcurrent/overvoltage)
    • Fault (ALM): Red (general module fault, e.g., overheating)
• Environmental Ratings:
  • Operating Temperature Range: 0℃~+40℃ (32℉~104℉; matches IRC5 controller’s operating environment)
  • Storage Temperature Range: -20℃~+60℃ (-4℉~140℉; no component degradation during storage)
  • Humidity Tolerance: ≤85% RH (non-condensing, 40℃; suitable for manufacturing floors)
  • Vibration Resistance: 10~500Hz, 1g acceleration (IEC 60068-2-6; no mechanical damage or connector loosening)
  • Shock Resistance: 15g acceleration (11ms duration, IEC 60068-2-27; maintains structural and electrical integrity)
  • Cooling Method: Convection cooling (passive; no fans—reduces dust ingress and maintenance)
• Compliance Standards: IEC 60950-1 (safety of information technology equipment), EN 61204-3 (power supplies for industrial use), UL 508 (industrial control safety), CE, RoHS

2. Key Features

• IRC5 Controller Exclusivity: Custom-engineered for ABB IRC5 systems—ensures perfect electrical matching with controller components (e.g., drives, I/O modules) and eliminates compatibility risks from generic power supplies.
• Universal AC Input (100V~240V): Auto-adapts to global power grids, enabling IRC5 robots to be deployed internationally without regional power supply modifications (critical for multi-site manufacturing operations).
• Multi-Channel Regulated DC Outputs: Provides four precise DC voltages (+5V, +24V, ±15V) to power all IRC5 subsystems—avoids the need for multiple standalone power supplies and simplifies controller wiring.
• Industrial-Grade Protection: Integrated overcurrent, overvoltage, short-circuit, and surge protection shields the IRC5 controller and robot from power anomalies (e.g., voltage spikes from nearby motors)—prevents costly damage and unplanned downtime.
• Low Ripple & Noise: ≤50mVpp ripple on key outputs minimizes electrical interference with robot encoders and sensors, ensuring accurate position control (critical for precision tasks like robotic welding or electronics assembly).
• Passive Convection Cooling: Fanless design reduces dust accumulation (a common cause of power supply failure in manufacturing environments) and eliminates fan maintenance—extends module service life to ≥7 years under normal operation.
• Intuitive LED Diagnostics: Front-panel LEDs for input power, individual DC outputs, and general faults enable technicians to quickly identify issues (e.g., a failed +24V output) without specialized test equipment.

3. Application Fields

• ABB IRC5 Robot Controller Power: Primary application—powers IRC5-based robot systems in:
  • Automotive Manufacturing: Supplies power to IRC5 controllers for welding robots (e.g., ABB IRB 6700), painting robots (e.g., ABB IRB 5500), and assembly line robots; ensures stable operation during high-volume production shifts.
  • Electronics Production: Powers IRC5 controllers for pick-and-place robots (e.g., ABB IRB 120) and PCB inspection robots; maintains low ripple power for encoder accuracy (critical for placing tiny SMT components).
  • Heavy Industry: Provides reliable power to IRC5 controllers for material handling robots (e.g., ABB IRB 7600) in steel mills or foundries; withstands vibration and electrical noise from large machinery.
• Precision Robot Operations: Enables accurate robot performance in:
  • Aerospace Manufacturing: Powers IRC5 controllers for robotic drilling and fastening robots (e.g., ABB IRB 7800); stable ±15V outputs ensure encoder precision for aircraft component assembly.
  • Pharmaceutical Packaging: Supplies power to IRC5-based robotic packagers (e.g., ABB IRB 460) in cleanrooms; fanless design avoids dust contamination and complies with GMP standards.
• Global Manufacturing Deployments: Supports international robot installations in:
  • European Factories: Operates on 230V AC, 50Hz grids to power IRC5 controllers for food processing robots (e.g., ABB IRB 360).
  • North American Plants: Adapts to 120V AC, 60Hz power for IRC5-based automotive assembly robots.
  • Asian Facilities: Works with 220V AC, 50Hz grids to power IRC5 controllers for electronics manufacturing robots.

4. Precautions

• IRC5 Only Compatibility: Use exclusively with ABB IRC5 robot controllers. Never install in older ABB controllers (e.g., S4C+) or non-ABB systems—electrical mismatches will damage the module, controller, or connected robot components.
• Input Power Compliance: Ensure incoming AC power matches the 100V~240V range. Do not connect to 3-phase AC power (the DSQC505 is single-phase only)—this will cause immediate module failure.
• Replacement Safety:
  • Disconnect the IRC5 controller from main power and discharge any residual voltage (wait 5 minutes) before replacing the module—prevents electrical shock.
  • Use only genuine ABB DSQC505 modules for replacement. Generic power supplies may not meet safety standards or provide stable voltages, leading to robot malfunctions or data loss.
• Overload Prevention: Do not exceed the maximum current rating of any DC output (e.g., 10A for +5V). Overloading causes the module’s OCP to trigger, shutting down the output and disrupting robot operation.
• Temperature & Ventilation: Ensure the IRC5 controller’s power compartment is well-ventilated. Operating the DSQC505 above +40℃ or in enclosed spaces with poor airflow causes overheating (indicated by the ALM LED) and reduces service life.
• Maintenance Checks: Inspect quarterly:
  • Verify all LEDs show normal status (AC green, DC outputs green, ALM off).
  • Check for loose connectors or damaged wiring (tighten connectors if wobbling; replace damaged wires immediately).
  • Clean the module’s ventilation slots with compressed air (avoid moisture) to remove dust—blocked slots cause overheating.
• Fault Handling: If the ALM LED illuminates:
  • Power off the IRC5 controller and disconnect AC power.
  • Check for short circuits in DC output wiring (e.g., a shorted +24V sensor).
  • If the fault persists, replace the DSQC505 module (do not attempt to repair—internal components are not field-serviceable).

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