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ABB DSQC661 Power Supply Module 

1. Key Parameters

• Product Model: DSQC661
• Order Code Reference: Typically paired with IRC5 system expansion kits (e.g., 3HAC031682-001) for procurement
• Product Series: ABB IRC5 Robot Controller Auxiliary Power Supply Modules
• Core Function: Converts AC mains power to regulated DC voltage for IRC5 peripherals; provides overload/short-circuit protection; supports redundant operation with another DSQC661 for fault tolerance
• 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: 10A (max at 100V AC); 5A (max at 240V AC)
  • Input Protection: 10A circuit breaker (thermal-magnetic; manual reset for overload/short-circuit)
• DC Output Specifications:
  • Output Voltage: 24V DC (regulated; nominal)
  • Output Voltage Tolerance: ±2% (ensures stable power for sensitive devices like encoders and sensors)
  • Output Current: 20A (continuous); 30A (peak, 10s duration for high-power device startup)
  • Ripple & Noise: ≤50mVpp (minimizes electrical interference with communication signals)
  • Output Protection:
    • Overcurrent Protection: Electronic current limiting (activates at 22A; prevents overload damage)
    • Short-Circuit Protection: <5ms response time (shuts down output to clear faults)
    • Overvoltage Protection: Clamps at 28V DC (protects devices from voltage spikes)
• Redundancy Features:
  • Redundancy Support: Configurable for 1+1 hot standby redundancy (with a second DSQC661)
  • Failover Time: ≤10ms (automatic switchover to redundant unit if primary fails)
  • Redundancy Communication: Proprietary redundancy bus (for status synchronization between units)
• Mechanical Specifications:
  • Housing Type: Metal heatsink with flame-retardant plastic cover (UL94 V-0; optimized for convection cooling)
  • Dimensions (W×H×D): 180mm × 220mm × 100mm (compact for integration in control cabinets)
  • Mounting: DIN rail-mounted (35mm standard DIN rail) + optional panel mounting
  • Weight: Approximately 2.2kg (includes integrated heatsink)
  • Connector Type: Screw terminals (input power); heavy-duty spring-clamp terminals (output power)
  • LED Indicators (on front panel):
    • Power Input (AC): Green (AC power present); Off (no input or breaker tripped)
    • DC Output (24V): Green (output normal); Amber (output current >80% of rating); Red (output fault)
    • Redundancy (RED): Green (redundant mode active); Amber (standby unit); Red (redundancy fault)
• Environmental Ratings:
  • Operating Temperature Range: 0℃~+50℃ (32℉~122℉; suitable for control cabinet installation)
  • Storage Temperature Range: -20℃~+70℃ (-4℉~158℉; no component degradation during storage)
  • Humidity Tolerance: ≤90% RH (non-condensing, 40℃; compatible with factory environments)
  • Vibration Resistance: 10~500Hz, 1g acceleration (IEC 60068-2-6; no mechanical damage)
  • Shock Resistance: 20g acceleration (11ms duration, IEC 60068-2-27; maintains structural integrity)
  • Cooling Method: Convection cooling (passive; no fans to reduce dust ingress and maintenance)
• Compliance Standards: IEC 60950-1 (safety of electrical equipment), EN 61204-3 (industrial power supplies), UL 508 (industrial control safety), CE, RoHS

2. Key Features

• IRC5 Peripheral Optimization: Designed specifically to power IRC5 peripherals (e.g., DSQC652 I/O units, robot grippers, tool changers)—ensures perfect voltage/current matching and eliminates compatibility issues with generic power supplies.
• High-Current Output: 20A continuous/30A peak current capacity supports multiple high-power devices (e.g., 4~5 heavy-duty grippers) in large robot cells—avoids the need for multiple standalone power supplies.
• 1+1 Redundancy Support: Configurable for hot standby redundancy with automatic ≤10ms failover—critical for mission-critical applications (e.g., automotive production lines) where peripheral power loss would halt production.
• Ultra-Low Ripple (<50mVpp): Minimizes electrical interference with sensitive devices like encoders, analog sensors, and communication buses—ensures reliable signal transmission in electrically noisy environments (e.g., near welding robots).
• Industrial-Grade Protection: Comprehensive overcurrent, short-circuit, and overvoltage protection shields connected peripherals from power anomalies—prevents damage to expensive equipment like robotic tool changers or vision systems.
• Passive Cooling Design: Fanless convection cooling reduces dust accumulation (a common cause of power supply failure in factories) and eliminates fan maintenance—extends service life to ≥8 years under normal operation.
• Universal Input (100V~240V): Auto-adapts to global power grids, enabling seamless deployment of IRC5 systems internationally without regional power supply modifications.

3. Application Fields

• IRC5 Peripheral Power Supply: Primary application—powers auxiliary devices in IRC5-based robot cells:
  • Automotive Manufacturing: Supplies power to DSQC652 distributed I/O units, welding torch actuators, and safety light curtains for multi-robot assembly lines; 20A capacity supports 8~10 peripherals per module.
  • Heavy Material Handling: Powers hydraulic grippers (high inrush current) and conveyor drive motors for IRB 8700 robots in steel mills; peak 30A output handles gripper startup currents without voltage drops.
  • Electronics Production: Provides stable 24V DC to vision systems, vacuum pumps, and SMT component feeders for IRB 120 pick-and-place robots; low ripple ensures camera image quality and sensor accuracy.
• Redundant Power Systems: Ensures uninterrupted power in:
  • Aerospace Manufacturing: Redundant DSQC661 units power critical tool changers and torque sensors for IRB 7800 drilling robots; ≤10ms failover prevents costly interruptions in aircraft component production.
  • Pharmaceutical Packaging: Redundant configuration supplies power to sterile grippers and cleanroom conveyors; eliminates risk of production halts due to power supply failure in GMP-compliant facilities.
• Large-Scale Robot Cell Expansion: Supports peripheral growth in:
  • Food & Beverage Processing: Powers additional washdown-compatible sensors, labelers, and palletizer grippers as production lines expand; universal input works with 230V (Europe) or 120V (North America) grids.
  • Warehouse Automation: Supplies power to robot-mounted scanners, conveyor diverters, and automated guided vehicle (AGV) interfaces in IRC5-controlled logistics systems; DIN rail mounting simplifies cabinet integration.

4. Precautions

• IRC5 System Compatibility: Use exclusively with ABB IRC5 robot systems and ABB-approved peripherals. Do not connect to non-IRC5 controllers or high-voltage devices (e.g., external heaters) exceeding the 24V/20A output limits—this will cause overload and permanent damage.
• Redundancy Configuration: When setting up 1+1 redundancy:
  • Use two identical DSQC661 units with matching firmware versions (check via ABB Service Tool). Mismatched units cause failover errors.
  • Connect both units to the same AC input phase (for synchronization) and ensure output loads are balanced between units.
• Overload Prevention:
  • Do not exceed the 20A continuous output rating. Calculate total load by summing all connected devices (e.g., 5A gripper + 3A I/O unit + 2A sensor = 10A total).
  • Limit peak current (30A) to 10s maximum—prolonged peak loads cause overheating and reduce service life.
• Wiring Guidelines:
  • Use heavy-gauge cables (minimum 12AWG) for output connections to minimize voltage drop, especially for long runs (>5m) to distant peripherals.
  • Connect the protective earth (PE) terminal to the control cabinet ground (resistance ≤1Ω) to ensure safety in case of insulation failure.
• Environmental Controls:
  • Install in a well-ventilated control cabinet with ambient temperature ≤50℃. Avoid direct sunlight or proximity to heat sources (e.g., motor drives)—high temperatures reduce output current capacity.
  • Keep the module’s heatsink free of dust and debris (clean with compressed air quarterly)—blocked cooling surfaces cause overheating (indicated by amber DC LED).
• Fault Handling:
  • If the DC output LED turns red (fault), disconnect AC power, check for short circuits in output wiring, and reset the module. If the fault persists, replace the unit (no field repairs possible).
  • In redundant systems, a red redundancy LED indicates a failover issue—check redundancy bus wiring and ensure both units have identical configurations.
• Replacement Guidelines: Replace only with genuine ABB DSQC661 modules. Generic replacements may not support IRC5 redundancy protocols or meet safety standards, risking peripheral damage or system downtime

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