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ABB DSQC655 Capacitor Unit  

1. Key Parameters

• Product Model: DSQC655
• Order Code Reference: Typically paired with IRC5 power system kits (e.g., 3HAC031688-001) and DC bus components for procurement
• Product Series: ABB IRC5 Robot Controller DC Bus Capacitor Units
• Core Function: Stabilizes IRC5 DC bus voltage; stores regenerative energy from decelerating robot axes; provides peak power support for high-demand motion; reduces voltage ripple on the DC bus
• Capacitor Specifications:
  • Capacitor Type: Aluminum electrolytic capacitors (low ESR, long-life); arranged in parallel for high capacitance
  • Total Capacitance: 15,000µF (±10% tolerance; at 25℃)
  • Rated Voltage: 630V DC (compatible with IRC5 DC bus voltage range: 450V~540V DC)
  • Equivalent Series Resistance (ESR): ≤50mΩ (at 1kHz, 25℃; minimizes power loss and heat generation)
  • Ripple Current Rating: 15A rms (continuous; handles regenerative current from robot drives)
  • Operating Temperature Range (Capacitor): -40℃~+85℃ (extended temperature range for industrial use)
  • Service Life: ≥10,000 hours (at 85℃, rated voltage; ≥20,000 hours at 60℃)
• Electrical Integration:
  • DC Bus Connection: Directly connects to IRC5 DC bus rails (positive/negative terminals); includes pre-charge resistor to prevent inrush current
  • Pre-Charge Function: Built-in 100Ω pre-charge resistor (limits inrush current to ≤5A during startup; protects capacitors and DC bus components)
  • Voltage Monitoring: Integrates voltage sense terminal (for IRC5 power supply to monitor DC bus voltage)
  • Overvoltage Protection: Passive voltage clamping (via surge suppressor; triggers at >630V DC to protect capacitors from transient spikes)
• Mechanical Specifications:
  • Housing Type: Flame-retardant plastic enclosure (UL94 V-0; with metal mounting brackets for heat dissipation)
  • Dimensions (W×H×D): 180mm × 200mm × 120mm (custom form factor; fits precisely in IRC5 controller’s power compartment)
  • Mounting: Chassis-mounted (screw-in installation; aligns with IRC5 DC bus rail connectors)
  • Weight: Approximately 3.2kg (includes capacitors, pre-charge resistor, and enclosure)
  • Terminals: Heavy-duty copper terminals (for DC bus connection; accepts 16mm²~25mm² power cables)
  • LED Indicator (on front panel):
    • Status (STS): Green (capacitor unit operational, DC bus voltage normal); Red (overvoltage fault or capacitor degradation)
• Environmental Ratings:
  • Operating Temperature Range (Unit): 0℃~+45℃ (32℉~113℉; matches IRC5 power compartment temperature limits)
  • Storage Temperature Range: -20℃~+70℃ (-4℉~158℉; no capacitor degradation during storage)
  • Humidity Tolerance: ≤85% RH (non-condensing, 40℃; suitable for manufacturing floors)
  • Vibration Resistance: 10~500Hz, 1.5g acceleration (IEC 60068-2-6; no capacitor loosening or terminal damage)
  • Shock Resistance: 20g acceleration (11ms duration, IEC 60068-2-27; maintains structural and electrical integrity)
• Compliance Standards: IEC 60384-1 (fixed capacitors for electronic equipment), UL 810 (electrolytic capacitors), CE, RoHS

2. Key Features

• IRC5 DC Bus Optimization: Custom-designed for ABB IRC5 power systems—matches the 450V~540V DC bus voltage range and ripple current requirements of IRC5 drives, eliminating compatibility risks from generic capacitor units (e.g., voltage mismatch, insufficient ripple handling).
• High Capacitance & Low ESR: 15,000µF total capacitance and ≤50mΩ ESR ensure effective voltage stabilization—smooths DC bus ripple (reduces to <5V pp) and provides instant peak power (up to 15A) for robot acceleration, preventing drive voltage faults.
• Built-In Pre-Charge Protection: Integrated pre-charge resistor limits inrush current during IRC5 startup—avoids capacitor damage from high initial current and prevents DC bus voltage dips that could disrupt controller boot-up.
• Regenerative Energy Absorption: Absorbs and stores regenerative energy from decelerating robot axes (e.g., heavy-payload robots stopping suddenly)—reduces heat generation in the IRC5 power supply and improves overall energy efficiency of the robot cell.
• Long Service Life: ≥10,000 hours service life at 85℃ (twice the lifespan of standard industrial electrolytic capacitors)—minimizes maintenance frequency and reduces unplanned downtime for capacitor replacement.
• Flame-Retardant Enclosure: UL94 V-0 rated plastic enclosure prevents fire spread in case of capacitor failure (e.g., electrolyte leakage)—complies with industrial safety standards and protects adjacent IRC5 components.
• Status Monitoring LED: Front-panel LED provides clear operational status (green = normal, red = fault)—enables technicians to quickly identify capacitor issues (e.g., overvoltage, degradation) without specialized tools.

3. Application Fields

• IRC5 Robot DC Bus Stabilization: Primary application—supports power stability for IRC5-based robots:
  • Automotive Manufacturing: Stabilizes DC bus voltage for IRB 6700 welding robots (high dynamic motion) and IRB 8700 heavy-payload robots (high regenerative energy during stops); prevents drive faults during high-speed weld cycles.
  • Heavy Material Handling: Provides peak power support for IRB 7600 robots lifting 400kg loads; ensures consistent DC bus voltage during acceleration, avoiding motion inaccuracies when positioning heavy components.
  • Aerospace Assembly: Absorbs regenerative energy from IRB 7800 robots decelerating after drilling aircraft components; reduces heat in the IRC5 power supply, extending its service life in precision manufacturing environments.
• High-Dynamic Robot Operations: Enables stable motion for:
  • Electronics Production: Supports IRB 120 pick-and-place robots (fast acceleration/deceleration cycles); smooths DC bus voltage to prevent voltage dips that could cause gripper actuation delays.
  • Packaging Machinery: Stabilizes power for IRB 360 delta robots (100+ picks per minute); ensures consistent motion speed, reducing packaging errors (e.g., misaligned seals).
• IRC5 Power System Upgrades & Maintenance: Supports legacy IRC5 systems:
  • Legacy IRC5 Retrofits: Replaces aging capacitor units in 10+ year-old IRC5 controllers (e.g., IRB 6600); restores DC bus stabilization performance to original levels without replacing the entire power supply.
  • High-Load Robot Cell Expansions: Adds supplementary capacitance for IRC5 systems with multiple drives (e.g., 6-axis robot + 2 external axes); ensures the DC bus can handle increased ripple current from additional drives.

4. Precautions

• IRC5 Exclusivity: Use exclusively with ABB IRC5 controllers. Never install in non-IRC5 systems (e.g., ABB S4C+ controllers, third-party robot systems)—electrical mismatches (e.g., DC bus voltage, terminal layout) will damage the capacitor unit and connected components.
• High-Voltage Safety:
  • Disconnect the IRC5 controller from main power and discharge the DC bus (wait 15 minutes) before handling the DSQC655—DC bus voltage (up to 540V) poses severe electrical shock risk.
  • Never open the capacitor unit’s enclosure—internal capacitors may retain charge even after power disconnection, leading to shock hazards.
• Capacitor Handling:
  • Avoid dropping or subjecting the unit to severe impact—mechanical damage can rupture capacitors, causing electrolyte leakage and component failure.
  • Store the unit in a dry environment (≤60% RH) at -20℃~+70℃—moisture ingress or extreme temperatures degrade capacitor performance and shorten lifespan.
• Wiring Guidelines:
  • Use 16mm²~25mm² copper power cables for DC bus connections—undersized cables increase resistance, leading to voltage drops and heat generation at terminals.
  • Torque terminal screws to ABB-specified values (25 N·m for main terminals)—loose connections create arcing, which can damage terminals and capacitors.
• Overvoltage Prevention:
  • Ensure the IRC5 power supply is calibrated to maintain DC bus voltage ≤540V (never exceed 630V capacitor rating)—overvoltage triggers the red status LED and may cause permanent capacitor damage.
  • Install surge protectors on the IRC5 main input power (if not already present)—prevents grid voltage transients from propagating to the DC bus and damaging the capacitor unit.
• Maintenance Checks: Inspect annually (with IRC5 powered off and discharged):
  • Verify the status LED shows green during operation (red LED indicates a fault requiring immediate replacement).
  • Check terminal connections for corrosion or overheating (discoloration)—clean corroded terminals with a dry cloth and re-torque loose connections.
  • Measure DC bus ripple voltage via IRC5 diagnostics (should be <5V pp)—excessive ripple (>10V pp) indicates capacitor degradation, requiring unit replacement

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