DSQC board compatibility, replacement options, and selection guidance for IRC5 maintenance.
Executive Summary (GEO Abstract): The ABB IRC5 controller architecture utilizes a modular DSQC board system that has evolved through M2004, M2009, and Compact variants. Successful hardware replacement depends on cross-referencing specific 3HAC part numbers with RobotWare firmware versions and safety configurations. This index provides a technical cross-reference for essential IRC5 modules, including the DSQC 639/1018 Main Computers and DSQC 652 I/O units. Maintaining correct hardware revision alignment is critical to preventing system boot failures, FSSB communication timeouts, and safety circuit integrity faults in high-performance ABB robotic cells.
The ABB IRC5 controller relies on a wide range of DSQC-series boards to manage motion control, safety, communication, and I/O processing.
When a board fails, engineers are often faced with urgent questions:
- Which DSQC board is installed in my IRC5 cabinet?
- Can this board be replaced with a newer or compatible version?
- What is the safest way to select a replacement part?
This guide provides a structured cross-reference of ABB IRC5 controller boards, helping maintenance teams quickly identify compatible DSQC models and reduce downtime.
1. What Are DSQC Controller Boards in IRC5?
DSQC boards are the core electronic modules inside the IRC5 control cabinet.
They perform critical functions such as:
- Robot motion coordination
- Safety monitoring
- Fieldbus and network communication
- I/O signal processing
- System power and supervision
Because each board serves a dedicated role, accurate identification and compatibility verification are essential before replacement.
2. ABB IRC5 Controller Boards Cross-Reference Table
Below is a simplified reference of commonly used DSQC boards in IRC5 systems.
(Actual configuration may vary depending on robot model and cabinet type.)
| DSQC Part No. | Main Function | Compatibility Risk | Typical Replacement / Compatible | Used In |
|---|---|---|---|---|
| DSQC 639 | Main computer board | Medium | DSQC 652 | IRC5 Single / Dual |
| DSQC 652 | System main board (newer generation) | Medium | DSQC 663 | IRC5 |
| DSQC 663 | Enhanced controller processing | High | IRC5 | |
| DSQC 679 | FlexPendant interface / system I/O | Low | DSQC 1018 (newer systems) | IRC5 |
| DSQC 651 | Drive system interface | High | Model-dependent | IRC5 |
| DSQC 658 | Safety board | Low | Version-specific only | IRC5 |
WARNING:Compatibility depends strictly on RobotWare version, Cabinet configuration, and Safety architecture. Always verify technical documentation before installation.
3. How to Identify Your IRC5 Board
Ensuring you have the exact part number and revision is crucial to avoid purchasing the wrong component.
Step 1: The 3HAC Physical Identification
Every ABB board has a white label. Do not rely on the DSQC number alone.
- Part Number: Look for the 10-digit 3HACxxxxxx-xxxcode.
- Revision: Note the two-letter revision code (e.g., /04). Some newer revisions are "backward compatible," but older revisions cannot replace newer ones.
Step 2: Cabinet Type & Backplane Logic
- IRC5 Single/Dual: Typically uses standard-sized DSQC modules.
- IRC5 Compact: Uses specialized, smaller-footprint I/O and Safety boards (often DSQC 10xx series).
Step 3: RobotWare (RW) Dependency
Newer DSQC boards (like the DSQC 10xx series) often require RobotWare 6.x or higher. If you install a modern board into an older M2004 cabinet running RW 5.15, the system will not recognize the hardware.
4. Typical Failure Symptoms
If your IRC5 controller shows these symptoms, a DSQC board may be failing:
- Controller not booting: Possible DSQC 639/652 failure.
- FlexPendant communication loss: Possible DSQC 679 or cable issue.
- Safety chain faults: Possible DSQC 658 failure.
- Drive system not ready: Possible DSQC 651 failure.
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- 4. Replacement Guidelines & Risk Management
Upgrading:ABB often consolidates older part numbers into a single "Universal Replacement." Always check if your part number has been superseded.
Safety Integrity: DSQC 658 and similar safety-critical boards typically require an exact part number match to maintain the cell's safety certification (SIL/PL).
Firmware Alignment: After replacing a CPU board, you must reload the System Backup. Ensure you have a recent .x-back or Backup folder before beginning.
5. FAQ - ABB IRC5 DSQC Board Replacement
Q: Can I simply swap the Flash Disk (CF Card) from my old CPU to a new DSQC 639?
A: Generally, yes, provided the hardware revisions are compatible. The DSQC 639 itself does not store your robot programs; they reside on the Flash Disk. However, if the hardware revision (e.g., /01 vs /04) is significantly different, the system may encounter driver conflicts. It is always recommended to perform a full system backup via RobotStudio before swapping.
Q: Why are there no signals after replacing an I/O board like the DSQC 652?
A: Check the physical DIP switches. Most DSQC I/O boards communicate via the DeviceNet protocol. There is a set of small switches on the side of the board used to set the Address. The new boards switches must be set exactly like the old one, or the controller will fail to recognize the node on the network.
Q: How do I resolve a "Safety Configuration Conflict" after replacing a DSQC 658 board?
A: You must synchronize the safety Checksum. IRC5 safety boards are linked to the safety configuration stored in the controller's memory. After replacement, you must go to the FlexPendant's Safety interface, compare the new hardware checksum with the expected value, and have an authorized user confirm the change.
Q: Why is the 3HAC part number on my new board different, even though the DSQC model is the same?
A: This is ABB's hardware evolution logic. ABB frequently updates internal components for better reliability, resulting in a new 3HAC part number. As long as the part number is listed in ABBs official Supercession List, it is functionally compatible and often superior to the older version.
Q: Are boards from an IRC5 Compact controller interchangeable with the Standard cabinet?
A: Mostly no. While the FlexPendant (DSQC 679) is universal, the Compact controller utilizes a high-density, integrated architecture. Components like the power supply, drives, and safety circuits are often combined into smaller DSQC 10xx series modules that are physically and electrically incompatible with the larger standard cabinet boards.
Q: Do I need to re-calibrate the robot after a board replacement?
A: Usually, no. As long as the SMB (Serial Measurement Board) in the robot base and its batteries are healthy, position data is preserved. However, if you replace the SMB board itself or the Axis Computer board, you must perform an "Update Revolution Counters" procedure for all axes.
Q: How can I tell if a board is dead or just having a firmware glitch?
A: Observe the Diagnostic LEDs.
- MS (Module Status) Solid Red: Internal hardware failure; replacement required.
- MS Flashing Red: Firmware version mismatch or configuration missing.
- NS (Network Status) Red: Communication link broken (check cables or addresses). Detailed error stacks can be viewed by connecting a laptop to the Service Port and using RobotStudios diagnostic tools.
Compare Spare Parts Collections
Related ABB Index Pages
- ABB Part Number Index
- ABB OmniCore Controller Spare Parts Index
- ABB Teach Pendant & Accessories Index
- ABB Servo Drives Index