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ABB DSQC508 Battery Unit  

1. Key Parameters

• Product Model: DSQC508
• Product Series: ABB IRC5 Robot Controller Backup Battery Units
• Core Function: Provides backup power to ABB IRC5 controllers during main power loss; preserves robot program data, encoder position data, and safety configuration; prevents data corruption and robot calibration loss
• Battery Specifications:
  • Battery Type: Sealed Lead-Acid (SLA) battery (maintenance-free; no electrolyte refilling required)
  • Nominal Voltage: 3.6V DC
  • Capacity: 2.2 Ah (ampere-hours; sufficient to power backup circuits for ≥72 hours during continuous outage)
  • Operating Temperature Range (Battery): 0℃~+40℃ (32℉~104℉; optimal performance within this range)
  • Service Life: ≥5 years (under normal operating conditions: 25℃ average temperature, <50 power outage cycles per year)
  • Charging Method: Automatic trickle charging via IRC5 controller (no manual charging required; controller maintains battery at full charge during normal operation)
• Electrical Specifications:
  • Input Power (from IRC5 Controller): 5V DC (regulated; supplied by the controller’s internal power module)
  • Charging Current: 10mA~20mA (trickle charge; prevents overcharging and extends battery life)
  • Backup Current Draw: ≤10mA (during power outage; ensures long backup duration)
  • Overcharge Protection: Built-in (via IRC5 controller’s charging circuit; prevents battery damage from excessive voltage)
• Mechanical Specifications:
  • Housing Type: Flame-retardant ABS plastic (UL94 V-0; resistant to impact and industrial dust)
  • Dimensions (W×H×D): 60mm × 30mm × 90mm (compact form factor; fits inside IRC5 controller chassis)
  • Mounting: Chassis-mounted (snap-in bracket; installed directly inside the IRC5 controller’s battery compartment—no external mounting required)
  • Weight: Approximately 200g
  • Connector Type: ABB proprietary 2-pin connector (keyed design; prevents reverse polarity connection and ensures secure mating with the IRC5 controller)
  • LED Indicator (on IRC5 Controller):
    • Battery Status (BAT): Green (battery fully charged and healthy); Amber (battery low charge or aging); Red (battery fault or failure)
• Environmental Ratings:
  • Operating Temperature Range (Unit): 0℃~+40℃ (32℉~104℉; matches IRC5 controller’s operating temperature)
  • Storage Temperature Range: -20℃~+50℃ (-4℉~122℉; no battery degradation during storage)
  • Humidity Tolerance: ≤85% RH (non-condensing, 40℃; suitable for manufacturing environments)
  • Vibration Resistance: 5~500Hz, 0.5g acceleration (IEC 60068-2-6; no mechanical damage or connector loosening)
  • Shock Resistance: 10g acceleration (11ms duration, IEC 60068-2-27; maintains battery integrity)
• Compliance Standards: IEC 62133 (secondary lithium-ion batteries—safety), UL 1973 (batteries for stationary applications), CE, RoHS

2. Key Features

• IRC5 Controller Exclusivity: Designed specifically for ABB IRC5 robot controllers—ensures perfect electrical and mechanical compatibility, eliminating the risk of data loss or controller damage from generic third-party batteries.
• Maintenance-Free SLA Battery: Sealed Lead-Acid (SLA) technology requires no electrolyte checks or refilling, reducing maintenance overhead for robot systems in high-volume manufacturing (e.g., automotive assembly lines).
• Automatic Trickle Charging: Powered and charged directly by the IRC5 controller’s internal circuit—maintains the battery at full charge during normal operation, ensuring it is always ready for power outages (no manual charging or monitoring needed).
• Long Backup Duration: 2.2 Ah capacity and ≤10mA backup current draw provide ≥72 hours of power to critical controller circuits, protecting robot programs and calibration data even during extended outages.
• Reverse Polarity Protection: Keyed 2-pin connector prevents incorrect installation (a common cause of battery failure or controller damage), ensuring safe, error-free replacement.
• Integrated Health Monitoring: Works with the IRC5 controller’s built-in battery status LED to provide clear visual feedback on battery health (charged/aging/faulty), enabling predictive replacement before failure (avoids unexpected data loss).
• Industrial-Grade Durability: Flame-retardant ABS housing and compliance with industrial vibration/shock standards ensure reliable operation in harsh manufacturing environments (e.g., automotive plants with heavy machinery vibration).

3. Application Fields

• ABB IRC5-Based Robot Systems: Primary application—powers backup circuits for IRC5 controllers in:
  • Automotive Manufacturing: Protects robot program data for welding, painting, and assembly robots (e.g., ABB IRB 6700) in automotive plants; prevents loss of production recipes or robot position calibration during power outages.
  • Electronics Production: Safeguards programming for pick-and-place robots (e.g., ABB IRB 120) used in SMT (Surface Mount Technology) lines; ensures no disruption to component placement accuracy after outages.
  • Food & Beverage Packaging: Preserves program data for robotic palletizers (e.g., ABB IRB 460) and packaging robots; maintains production continuity by avoiding reconfiguration after power restoration.
• High-Downtime-Cost Environments: Critical for robot systems where downtime is expensive:
  • Aerospace Manufacturing: Protects complex programming for robotic drilling and fastening robots (e.g., ABB IRB 7600) used in aircraft assembly; prevents weeks of re-calibration if power is lost.
  • Pharmaceutical Production: Safeguards robot programs for sterile filling robots (e.g., ABB IRB 4600) in GMP-compliant facilities; avoids costly revalidation of processes due to data loss.
• Extended Outage Prone Areas: Essential for facilities with frequent or long power outages:
  • Remote Manufacturing Sites: Protects robot systems in locations with unstable power grids (e.g., rural industrial parks); ensures robot data is preserved during utility outages.
  • Disaster-Prone Regions: Safeguards robot controllers in areas prone to storms or grid failures (e.g., coastal factories); maintains robot functionality once power is restored.

4. Precautions

• IRC5 Only Compatibility: Use exclusively with ABB IRC5 robot controllers. Never use with older ABB controllers (e.g., S4C+) or non-ABB robot systems—electrical mismatches will damage the battery, controller, or both.
• Battery Replacement Timing: Replace the battery every 5 years (or earlier if the IRC5 controller’s BAT LED shows amber/red). Using an aging battery increases the risk of insufficient backup power and data loss during outages.
• Replacement Safety:
  • Disconnect the IRC5 controller from main power before replacing the battery (prevents electrical shock or short circuits).
  • Use only genuine ABB DSQC508 batteries for replacement—generic batteries may not meet safety standards or provide adequate backup duration.
• Charging Limitations: Do not charge the battery outside the IRC5 controller (e.g., with a third-party charger). The controller’s dedicated circuit is calibrated for trickle charging; external chargers cause overcharging and battery failure.
• Temperature Restrictions: Avoid operating or storing the battery outside the 0℃~+40℃ range. High temperatures (>40℃) reduce battery service life; low temperatures (<0℃) decrease backup capacity (may not provide 72 hours of power).
• Disposal Compliance: Dispose of old batteries in accordance with local environmental regulations (SLA batteries are classified as hazardous waste in most regions). Do not incinerate or landfill—use authorized battery recycling facilities.
• Post-Replacement Checks: After installing a new battery:
  • Reconnect the IRC5 controller to main power and verify the BAT LED turns green (indicates proper charging).
  • Test the backup function by temporarily disconnecting main power (ensure the controller retains program data when power is restored)

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