1 2 3 4 5 6 7 8

The information in this document is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

Except as may be expressly stated anywhere in this document, nothing herein shall be construed as any
kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a
We reserve all rights in this document and in the information contained therein.Reproduction, use or

specific purpose or the like.

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

In no event shall ABB be liable for incidental or consequential damages arising from use of this document.

This document and parts thereof must not be reproduced or copied without ABB's written permission,
and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.
Contravention will be prosecuted.

Additional copies of this document may be obtained from ABB at its then current charge.

© Copyright 2004 ABB ALL right reserved.

ABB Automation Technologies AB

Robotics
SE-721 68 Västerås
Sweden

Latest revision: Lab/Office: Status: Plant: = SP

SWC IRC5 M2004 Location: +
Rev. 07 APPROVED
CM 500000056877 Sublocation: +
COPYRIGHT PAGE Document no. Rev. Ind Page 1
Next 2
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 SPOT PACK 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

Customer :
Robot serial number(s) :
Drawing number :
Drawing version :
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

Manufacture :
Type :
Type of installation :
Control cabinet :
Mains voltage :
Supply :
Control voltage :
Year of construction :

Project start :
Project manager :
Last revision :
Designed by :
Designed date :
Number of pages :
:

Latest revision: Lab/Office: Status: Plant: = SP

SWC IRC5 M2004 Location: +
Rev. 07 APPROVED
CM 500000056877 Sublocation: +
TITLE PAGE Document no. Rev. Ind Page 2
Next 3
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 SPOT PACK 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

Table of contents ABB_table_of_contents

Plant Location Page Page description Remark Date Editor

SP 1 COPYRIGHT PAGE 2013-04-25 Thomas
SP 2 TITLE PAGE 2013-04-25 Thomas
SP 3 TABLE OF CONTENTS 2013-04-25 Thomas
SP S 50 BLOCK DIAGRAM TYPE S 2013-04-25 Thomas
SP S 51 BLOCK DIAGRAM TYPE S - IRBDP SW5 2013-04-25 Thomas
SP HS 52 BLOCK DIAGRAM TYPE HS 2013-04-25 Thomas
SP Se 53 BLOCK DIAGRAM TYPE Se 2013-04-25 Thomas
SP Se 54 BLOCK DIAGRAM TYPE Se - IRBDP SW5 2013-04-25 Thomas
SP HSe 55 BLOCK DIAGRAM TYPE HSe 2013-04-25 Thomas
SP CAB 56 VIEW SPOT WELDING CABINET - STANDARD 2013-04-25 Thomas
SP CON 57 CONNECTOR LAYOUT - IRBDP SW5 2013-04-25 Thomas
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

SP CAB 58 VIEW SPOT WELDING CABINET 2013-04-25 Thomas

SWCA P.24V 100 BOSCH AC/MFDC 2013-04-25 Thomas
SWCE P.24V 101 BOSCH AC/MFDC 2013-04-25 Thomas
SWC P.24V 102 COMPACT BOSCH AC 2013-04-25 Thomas
SWC P.B 103 BOSCH AC/MFDC 2013-04-25 Thomas
SWC P.B 104 COMPACT BOSCH AC 2013-04-25 Thomas
SWCAE B 105 BOSCH AC/MFDC 2013-04-25 Thomas
SWC B 106 COMPACT BOSCH AC 2013-04-25 Thomas
SWC S.B 107 COMPACT BOSCH AC 2013-04-25 Thomas
SWCAE RG 108 BOSCH AC/MFDC 2013-04-25 Thomas
SWCAE PG 109 BOSCH AC/MFDC 2013-04-25 Thomas
WA_AE SWC 110 BOSCH AC/MFDC 2013-04-25 Thomas
WA_AE SB 111 BOSCH AC/MFDC 2013-04-25 Thomas
WA_AE SB 112 BOSCH AC/MFDC 2013-04-25 Thomas
WA S 113 COMPACT BOSCH AC 2013-04-25 Thomas

Latest revision: Lab/Office: Status: Plant: = SP

SWC IRC5 M2004 Location: +
Rev. 07 APPROVED
CM 500000056877 Sublocation: +
TABLE OF CONTENTS Document no. Rev. Ind Page 3
Next +S/50
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 SPOT PACK 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

BLOCK DIAGRAM TYPE S (pneumatic gun)

IRBDP SW2
Single cabinet controller, IRC5: See circuit diagram, 3HAC024480-004.
Dashed cables: See circuit diagram DressPack, 3HAC026209-001

SPOT WELDING
24VDC SUPPLY, PARALLEL INTERFACE, PROP. VALVE XP/XS103 CABINET

WELD POWER X101

We reserve all rights in this document and in the information contained therein.Reproduction, use or

Axis 5 Axis 3
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

R3.CP/CS R2.CP/CS

WATER AND XP/XS113

AIR UNIT

24VDC SUPPLY, WELDING SIGNALS

Axis 6 Axis 4

CANBUS INTERFACE
XS/XP101

RS232/RS485
115/230VAC
Axis 2

Axis 1
R1.WELD
Base ROBOT SIGNALS, 24VDC SUPPLY XP/XS13
SINGLE CABINET
CONTROLLER
R1.CP/CS/CBUS

Latest revision: Lab/Office: Status: Plant: = SP

REGION E & A SWC IRC5 M2004 +S
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: +
BLOCK DIAGRAM TYPE S Document no. Rev. Ind Page 50
Next 51
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 SPOT PACK 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

BLOCK DIAGRAM TYPE S (pneumatic gun)

IRBDP SW5
Single cabinet controller, IRC5: See circuit diagram, 3HAC024480-004.

SPOT WELDING
CUSTOMER POWER SWC.24V CABINET
CUSTOMER SIGNAL SWC.I/O
We reserve all rights in this document and in the information contained therein.Reproduction, use or

Axis 5 Axis 3 WELD POWER SWC.WELD

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

R3.CP/CS R2.CP/CS

24VDC SUPPLY, WELDING SIGNALS

WATER AND
AIR UNIT
Axis 6 Axis 4

CANBUS INTERFACE

RS232/RS485
CONNECTION BOX
Axis 2

3HAC029444-001

3HAC029486-001
3HAC029446-001
R1.WA
R1.CB
R1.CB
Axis 1
R1.WELD

Base
SINGLE CABINET
CONTROLLER

Latest revision: Lab/Office: Status: Plant: = SP

REGION E SWC IRC5 M2004 +S
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: +
BLOCK DIAGRAM TYPE S - IRBDP SW5 Document no. Rev. Ind Page 51
Next +HS/52
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 SPOT PACK 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

BLOCK DIAGRAM TYPE HS (material handling and pneumatic gun)

IRBDP SW2
Single cabinet controller, IRC5: See circuit diagram, 3HAC024480-004.
Dashed cables: See circuit diagram DressPack, 3HAC026209-001

SPOT WELDING
24VDC SUPPLY, PARALLEL INTERFACE, PROP. VALVE XP/XS103 CABINET

Axis 5 Axis 3
R3.CP/CS R2.CP/CS X101
X104
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

WATER AND XP/XS113

AIR UNIT

24VDC SUPPLY, WELDING SIGNALS

Axis 6 Axis 4

CANBUS INTERFACE
XS/XP101

RS232/RS485
115/230VAC
Axis 2

Axis 1

R1.CP/CS/CBUS ROBOT SIGNALS, 24VDC SUPPLY XP/XS13

Base SINGLE CABINET
CONTROLLER

PEDESTAL
GUN

SG.WELD WELD POWER

SG.CP/CS WELDING SIGNALS, 24VDC SUPPLY

Latest revision: Lab/Office: Status: Plant: = SP

REGION E & A SWC IRC5 M2004 + HS
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: +
BLOCK DIAGRAM TYPE HS Document no. Rev. Ind Page 52
Next +Se/53
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 SPOT PACK 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

BLOCK DIAGRAM TYPE Se (servo gun)

IRBDP SW2
Single cabinet controller, IRC5: See circuit diagram, 3HAC024480-004.
Dashed cables: See circuit diagram DressPack, 3HAC026209-001

SPOT WELDING
24VDC SUPPLY, PARALLEL INTERFACE XP/XS103 CABINET

WELD POWER X101

Servo gun Axis 5 Axis 3
( axis 7 )
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

Axis 6 Axis 4 R2.CP/CS

R3.CP/CS R2.WELD XP/XS113
WATER AND
R3.WELD
AIR UNIT

24VDC SUPPLY, WELDING SIGNALS

CANBUS INTERFACE
XS/XP101

RS232/RS485
115/230VAC
Axis 2

Axis 1
R1.WELD
Base

R1.CP/CS/CBUS ROBOT SIGNALS, 24VDC SUPPLY XP/XS13

SINGLE CABINET
R1.SP SERVO GUN POWER XP/XS7 CONTROLLER

Latest revision: Lab/Office: Status: Plant: = SP

REGION A SWC IRC5 M2004 + Se
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: +
BLOCK DIAGRAM TYPE Se Document no. Rev. Ind Page 53
Next 54
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 SPOT PACK 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

BLOCK DIAGRAM TYPE Se (servo gun)

IRBDP SW5
Single cabinet controller, IRC5: See circuit diagram, 3HAC024480-004.
Dashed cables: See circuit diagram DressPack, 3HAC026209-001

SPOT WELDING
CUSTOMER POWER SWC.24V CABINET
CUSTOMER SIGNAL SWC.I/O
WELD POWER SWC.WELD
Servo gun Axis 5 Axis 3
( axis 7 )

24VDC SUPPLY, WELDING SIGNALS

We reserve all rights in this document and in the information contained therein.Reproduction, use or

WATER AND
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

M
AIR UNIT

CANBUS INTERFACE
Axis 6 Axis 4 R2.CP/CS
R3.CP/CS R2.WELD

RS232/RS485
R3.WELD

CONNECTION BOX

3HAC029444-001

3HAC029486-001
Axis 2

3HAC029446-001
R1.CB
R1.CB
R1.CB
Axis 1
R1.WELD

Base R1.SP SERVO GUN POWER XP/XS7

SINGLE CABINET
CONTROLLER

Latest revision: Lab/Office: Status: Plant: = SP

REGION E SWC IRC5 M2004 + Se
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: +
BLOCK DIAGRAM TYPE Se - IRBDP SW5 Document no. Rev. Ind Page 54
Next +HSe/55
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 SPOT PACK 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

BLOCK DIAGRAM TYPE HSe (material handling and servo gun)

IRBDP SW2
Single cabinet controller, IRC5: See circuit diagram, 3HAC024480-004.
Dashed cables: See circuit diagram DressPack, 3HAC026209-001

24VDC SUPPLY, PARALLEL INTERFACE, PROP. VALVEXP/XS103 SPOT WELDING

CABINET

Axis 5
Axis 3 X101

X104
We reserve all rights in this document and in the information contained therein.Reproduction, use or

XP/XS113
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

WATER AND
AIR UNIT

R2.CP/CS

24VDC SUPPLY, WELDING SIGNALS

Axis 6 Axis 4
R3.CP/CS R2.WELD
R3.WELD

CANBUS INTERFACE
XS/XP101

RS232/RS485
115/230VAC
Axis 2

Axis 1

R1.CP/CS/CBUS ROBOT SIGNALS, 24VDC SUPPLY XP/XS13

Servo gun Base SINGLE CABINET
CONTROLLER
( axis 7 )
R3.FB7

M PEDESTAL FB.M7 RESOLVER/SMB SIGNALS

GUN

R1.SP POWER SERVOGUN XP/XS7

SG.WELD WELD POWER

SG.CP/CS WELDING SIGNALS, 24VDC SUPPLY

Latest revision: Lab/Office: Status: Plant: = SP

REGION A SWC IRC5 M2004 + HSe
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: +
BLOCK DIAGRAM TYPE HSe Document no. Rev. Ind Page 55
Next +CAB/56
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 SPOT PACK 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

LEFT A-A FRONT LEFT BACK

B A B

X101
FZ101
135
QC101
VE101
MED
246

K103
MS101

A
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

QI101 (MFDC)
QI101 (AC)

CONNECTION PLATE CONNECTION PLATE

DOOR TOPP B-B

XP/XS100
FU100
Front side

XP113 XS105 X104 XS103 XP113 XS105 X104 XS103

XT6.1 XT5.4 XT5.5 XT6.1 XT6.2 XT5.4 XT5.5

QB101 U
LINE
LINE

U U

LINE
LINE
LINE
LINE
LOAD
LOAD

LOAD
LOAD
LOAD
LOAD
A1(+)
T1L1

A1(+)
A1(+)

T1L1
T1L1
A2(-)

1234

A2(-)
D 1234

A2(-)
1234 Back side D

XT101 K101 XT5.6 XT101 XT5.6

K102 K101

REGION A REGION E

Latest revision: Lab/Office: Status: Plant: = SP

REGION A SWC IRC5 M2004 + CAB
Rev. 07 Location:
CM 500000056877
REGION E APPROVED Sublocation: +
VIEW SPOT WELDING CABINET - STANDARD Document no. Rev. Ind Page 56
Next +CON/5
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 SPOT PACK 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

BLOCK DIAGRAM TYPE S

XT5.1 XT5.2 XT5.3

3HAC029470-001 3HAC029470-001
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

XS8.1 XS8.3

XP5.3

3HAC029396-001
3HAC029396-001

XS8.2 XS8.3
XS8.1

XP5.1 XP5.2

3HAC029393-001 3HAC029393-001 3HAC029393-001 3HAC029393-001

Latest revision: Lab/Office: Status: Plant: = SP

REGION E SWC IRC5 M2004 + CON
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: +
CONNECTOR LAYOUT - IRBDP SW5 Document no. Rev. Ind Page 57
Next +CAB/58
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 SPOT PACK 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

LEFT A-A TOP B-B FRONT RIGHT C-C

XS/XP100
A C
FU100

X3C
1 3 5

12345678910
MED
2 4 6
I/O BOARD 1
QB101
B B
We reserve all rights in this document and in the information contained therein.Reproduction, use or

XT101 XT5.1 XT5.2 XT5.3

disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

A C VE101

DOOR LEFT BACK

CONNECTION PLATE Back side CONNECTION PLATE Front side

CABLE INLET
CABLE INLET

X101

Latest revision: Lab/Office: Status: Plant: = SP

REGION A SWC IRC5 M2004 + CAB
Rev. 07 Location:
CM 500000056877
REGION E APPROVED Sublocation: +
VIEW SPOT WELDING CABINET Document no. Rev. Ind Page 58
Next =SWCA+
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 SPOT PACK 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

SEE PAGE 109, 111 and 113

ROBOT GUN (RG)
PEDESTAL GUN (PG) .6 -F5 -F4
WATER AND AIR UNIT-SWC OPTION: 2 OPTION: 3
+24VDC 0VDC SERVICE SERVICE
-XT31 OUTLET OUTLET
2 6

-XS/XP61 115/230VAC 0VAC

-F5
1 2 12 11
2 N(0)

SINGLE
CABINET

POWER 1, BK 2, BK GNYE
CP/CS 9:WHRD 6:WH 4:WH 7:WH 5:WH 9:RD 10:YE 10:WHYE
3
35 0,75 0,75 0,75 0,75

-XS/XP113
B1 A3 A1 A4 B2 B12 B11 A11 A12 PE
A2
OG

AWG16 OG

AWG16 OG
-1027

-1025

AWG18 OG

AWG18 OG

AWG18 OG
SPOT -1029 -1030
AWG16

-1026

-1095

-1096

-1011
WELDING AWG16 OG AWG16 OG AWG16 GNYE
CABINET
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

AWG16 OG -1083
AWG18 OG

-K103
OPTION 873
-XT101
13 A1

-K101
OPTION 790-1
8 7 6 5
4 3 2 1 A1(3+) 2
2A 2A 2A 2A
14 A2
AWG16 OG

A2(-4) 1
-1076
-1092
-1091 AWG18 OG AWG16 OG

-1084 AWG18 OG AWG18 OG

-1075
-1090 AWG18 OG -1093 AWG16 OG

-1078 AWG18 OG
OG

AWG18 OG

AWG18 AWG18
AWG18 OG

OG
-1085

-1099
-1014

OG
AWG18
-1013

-K102
AWG18 -1082
-1086AWG16

-1100 OG
A1(-) 9

A2(+) 5
-1077
AWG18 OG AWG16 OG
OG

OG

-1079
-XT5.6 -XT5.5 -XT5.4 -XT6.1
-1094AWG18

-1098AWG20

1 2 1 2 11 3 4 7 2 11 1 12 5 6 1 2 3 4 5

OG

OG

OG

OG
XS/XP103

-1073 AWG20

-1074 AWG20

-1067 AWG18

-1068 AWG18

-1069 AWG18

-1070 AWG18

-1072 AWG20

-1071 AWG20
VE101
+.-1043

+.-1044

+.-1053

+.-1033

+.-1034

+.-1037

+.-1032

+.-1031

+.-1035

BOSCH AC/MFDC - SIGNAL OR / +.-1036

X104

X104

/
14 21
SEE PAGE 111

AIR UNIT-SWC
SEE PAGE 113

.8 AWG21 1,BK 2,BK

WATER AND
-QB101
-MS101

SEE PAGE 105, 106 or 107

2
PEDESTAL
GUN (PG)

13 24

MEDAR AC - SIGNAL OR
MEDAR MFDC - SIGNAL
12 14 FAN UNIT 11 A1 C1
-QC101

-QC101

-QB101

-QC101

-QB101
-XS100 -FZ101
OPTION: OPTION:
11 13 788-1 .8 14 790-1 A2 C2
-1097 1 3
AWG20 OG
OPTION: OPTION: OPTION:
11 12 .3 14 11 .6
873 MEDAR BOSCH
13 14 .4 21 24 .1
TIP DRESSER AC/MFDC AC/MFDC

Latest revision: Lab/Office: Status: Plant: = SWCA

REGION A SWC IRC5 M2004 +P
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: + 24V
BOSCH AC/MFDC Document no. Rev. Ind Page 100
Next =SWCE/
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 POWER SUPPLY, 24VDC, 115/230VAC 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

SEE PAGE 109, 111 and 113

ROBOT GUN (RG)
PEDESTAL GUN (PG) .6 -F5 -F4
OPTION: 2 OPTION: 3
+24VDC 0VDC WATER AND AIR UNIT-SWC
SERVICE SERVICE
-XT31 OUTLET OUTLET
2 6
115/230VAC 0VAC
-XS/XP61
-F5
1 2 12 11 2 N(0)

SINGLE
CABINET

CP/CS 9:WHRD 6,WH 4,WH 7,WH 5,WH 9:RD 10:YE 10:WHYE POWER 1, BK 2, BK GNYE

35 0,75 0,75 0,75 0,75 3

-XS/XP113
B1 A3 A1 A4 A2 B2 B12 B11 A11 A12 PE
AWG16 OG

AWG16 OG

AWG16 OG

AWG16 OG

AWG18 OG

AWG18 OG

AWG18 OG
SPOT -1029 -1030
-1027

-1025

-1028

-1026

-1095

-1096

-1011
WELDING AWG16 OG AWG16 OG AWG16 GNYE
CABINET
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

AWG16 OG

-K103
OPTION 873
-XT101
13 A1
8 7 6 5
2A 2A 2A 2A 4 3 2 1
14 A2

-1099 AWG18 OG

-1091 AWG18 OG -1083AWG18 OG

-1084 AWG18 OG

-K101
OPTION 790-1
-1090 AWG18 OG
A1(3+) 2
-1079 AWG18
OG

AWG18 OG

AWG18 OG

AWG18 OG

OG
-1085

-1014

-1086

-1078
AWG18
A2(-4) 1
-1013 AWG18

-1100 AWG18 OG

-1077 AWG18 OG AWG18 OG AWG16 OG AWG16 OG

-1080 AWG18 OG -1082 -1075 -1076

-1081 AWG18 OG
OG

OG

-XT5.6 -XT5.5 -XT6.2 -XT5.4 -XT6.1

-1094AWG18

-1098AWG18

1 2 1 2 11 1 2 3 4 3 4 7 2 11 1 12 5 6 1 2 3 4
OG

OG

OG

OG

OG

OG

OG

OG
XS/XP103

-1071 AWG20

-1072 AWG20

-1073 AWG20

-1074 AWG20

-1067 AWG18

-1068 AWG18

-1069 AWG18

-1070 AWG18
VE101
+.-1043

+.-1044

+.-1053

+.-1033

+.-1034

+.-1037

+.-1032

+.-1031

+.-1035

/ +.-1036
X104

X104

BOSCH AC/MFDC - SIGNAL OR

14 23
AIR UNIT-SWC
SEE PAGE 111

SEE PAGE 113

.3 AWG21 1,BK 2,BK

WATER AND
-MS101

-QB101

SEE PAGE 105, 106 or 107

2
PEDESTAL
GUN (PG)

13 24

MEDAR AC - SIGNAL OR
MEDAR MFDC - SIGNAL
C1 12 14 FAN UNIT 11 A1
-QB101

-QC101

-QC101

-QB101

-QC101
-XS100 -FZ101
OPTION: OPTION:
C2 11 13 788-1 .3 14 790-1 A2
-1097 1 3
AWG20 OG
OPTION: 14 11 .7 OPTION: OPTION:
873 23 24 .1 11 12 .4
MEDAR BOSCH
TIP DRESSER 13 14 .4
AC/MFDC AC/MFDC

Latest revision: Lab/Office: Status: Plant: = SWCE

REGION E SWC IRC5 M2004 +P
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: + 24V
BOSCH AC/MFDC Document no. Rev. Ind Page 101
Next =SWC/1
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 POWER SUPPLY, 24VDC, 115/230VAC 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

0V 24V
-XT31
6 2

-K42 -K43
-1001 33 34 -1002 33 34
AWG18 BU AWG18 BU
SINGLE
CABINET

3HAC029446-001
-3HAC15620-1 4BK 3BK 1BK 2BK

AWG18

=SWCE-832 AWG18 OG
SPOT
WELDING
CABINET -XT101
8 7 6 5
10 9 2A 2A 2A 2A 4 3 2 1
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

AWG18 OG

AWG18 OG

AWG18 OG

AWG18 OG

AWG18 OG

AWG18 OG
-1026

-1025

-1031

-1032

-1013

-1014
TIMER
BOSCH
-X1S2

2 1
TIMER
BOSCH
-X1S1 -XT/XP5.3
2 1 3 4 5 6 1 2 3 4
-831
AWG18 OG

-830 -830 -830

AWG18 OG AWG18 OG AWG18 OG 0V 24V 24V 0V
AWG18 OG

AWG18 OG

-3HAC15620-1 1BK 2BK 3BK 4BK

-830

-831

AWG18
-AWG21 2 1

FAN UNIT
-I/OB1 -I/OB1 -I/OB1 -I/OB1 -XS100
X1 X3 X4 X2
.2 .2 .2 .2 OPTION:
.3 9 10 .3 9 10 .2 9 10 .2 9 10 788-1
.4 .4 .4 .3 3 1

0V 24V 0V 0V 0V 24V 0V 24V

CONNECTION
BOX -XS/XP8.1 -XS/XP8.3
1 2 1 4

24V 0V 24V 0V

Latest revision: Lab/Office: Status: Plant: = SWC

REGION E SWC IRC5 M2004 +P
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: + 24V
COMPACT BOSCH AC Document no. Rev. Ind Page 102
Next +.B/103
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 POWER SUPPLY, 24VDC 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

Incomming phases Incomming phases

(Customer) SPOT WELDING CABINET (Customer) SPOT WELDING CABINET

L1 L1

L2 L2

L3 L3

PE PE

1 3 5 1 3 5

-QB101 -QB101
I> I> I> I> I> I>
-1101AWG16(10) BK -1101AWG16(10) BK
2 4 6 2 4 6
-1102AWG16(10) BK -1102AWG16(10) BK

GNYE

GNYE

GNYE

GNYE
-1103AWG16(10)

BK

BK

BK

BK
-MS101 BK -1103AWG16(10) BK

-PE AWG4

-PE AWG4

-PE AWG4

-PE AWG4
OPTION 873 -MS101
1 3 5
OPTION 873
1 3 5
-RD

-RD

-RD

-RD

-RD

-RD

-RD

-RD
I> I> I>
2 4 6
1 2 3 N I> I> I> 1 2 3 N
We reserve all rights in this document and in the information contained therein.Reproduction, use or

2 4 6
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

-QI101 -QI101
AWG16 BK

AWG16 BK

AWG16 BK

AWG16 BK

AWG16 BK

AWG16 BK
-1104

-1105

-1106

-1104

-1105

-1106
EARTH FAULT EARTH FAULT
PROTECTION PROTECTION
1 2 3 N 1 2 3 N
2T1 4T2 6T3 2T1 4T2 6T3
-K103 -K103
BK

BK

BK

BK

BK
OPTION 873 OPTION 873
1L1 3L2 5L3 1L1 3L2 5L3
-U1A AWG1

-V1A AWG1

-U1A AWG1

-V1A AWG1

-W1A AWG1
AWG16 BK

AWG16 BK

AWG16 BK

AWG16 BK

AWG16 BK

AWG16 BK
-1107

-1108

-1109

-1107

-1108

-1108
GNYE

-VE101 -VE101
AWG16

U1 V1 PE U1 V1 W1 PE
BOSCH BOSCH
AC MFDC

U2 V2 U2 V2
-XS/XP105 1 2 3 PE -XS/XP105 1 2 3 PE
OPTION 873 OPTION 873
BK

BK

BK

BK
-U1B AWG1

-V1B AWG1

=-U1B AWG4

-V1B AWG4
1 2 3 GNYE 1 2 3 GNYE

2T1 4T2 6T3 2T1 4T2 6T3

-QC101 -X101 -QC101 -X101
OPTION 790-1 OPTION 790-1
1L1 3L2 5L3 1L1 3L2 5L3

PE PE

V V
U1 V1 W1 U1 V1 W1

M U M U

OPTION 807-1 3~ OPTION 807-1 3~

TIP DRESSER TIP DRESSER
PE ALT 1) BOSCH AC Outgoing phases PE ALT 2) BOSCH MFDC Outgoing phases

Latest revision: Lab/Office: Status: Plant: = SWC

REGION A & E SWC IRC5 M2004 +P
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: + B
BOSCH AC/MFDC Document no. Rev. Ind Page 103
Next 104
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 POWER - WELD TIMER PHASES 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

Incomming
phases
(Customer) SPOT WELDING CABINET

L1

L2

L3

PE

1 3 5

-QB101
I> I> I>
2 4 6
3HAC025166-001

GNYE
BK

BK
We reserve all rights in this document and in the information contained therein.Reproduction, use or

AWG4
-U1A AWG1

-V1A AWG1
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

-PE

-VE101

BOSCH
COMPACT
1BK

2BK
-U1B

-V1B

3HAC029395-001 3HAC029392-001
-3HAC17137-1 -3HAC3730-1
-X101 -R2.WELD -R3.WELD

GNYE GNYE
PE
1
2BK 2BK
V
2
1BK 1BK
U
3

Outgoing
phases

ALT 3) BOSCH COMPACT

Latest revision: Lab/Office: Status: Plant: = SWC

REGION E SWC IRC5 M2004 +P
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: + B
COMPACT BOSCH AC Document no. Rev. Ind Page 104
Next =SWCAE
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 POWER - WELD TIMER PHASES 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

SHIELD

CAN_H

CAN_L

V-REG

V-REG

Rx+
Tx+
KSR

KSR
24V

Rx-
Tx-
0V

0V
-A35.X2

+.AC-XP60

-A39.X1
3 5 1 4 2 23 24 21 22 1 3 2 9 5

SINGLE
CABINET

4:WHOG

2:WHOG

3:WHGN
1:WHBU
5:WHYE
1/WH

4:OG

2:OG

3:GN
2/RD

1/BU

1:BU
2/BK

5:YE
+.AC-3HAB8277 CP/CS AWG26
5 AWG24 8
35
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

OPTION: 796-1
EPV

-XS/XP113

-XS/XP103
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 8

SEE PAGE: 100 or 101 SEE PAGE: 109 or 111

SPOT POWER SUPPLY RG or SG AWG16 GNYE

WELDING
CABINET
-XT5.4

AWG26
-3HAB8277 2/RD 2/BK 1/WH 1/BU AWG24 RD BK 4x BU BU/WH OG OG/WH AWG24 RD BK
1 2 3 4 5 6 7 8 9 10 11 12
5 2 2
OG

OG

OG
-1033

-1035

-1034

-1036 OG
OG

OG

AWG18 OG

AWG18 OG

-1087 -1041 -1042 -1038 -1039

-1037

-1040
-1031
AWG18

-1032

AWG18 OG OG OG AWG18 OG OG AWG18 OG AWG18 OG AWG20 BU

-VE101
=SWCAE+B-X13

BOSCH 3 5 1 4 2
AC/MFDC
X10-1

X10-2

X4-10

X4-11

X4-12
X4-6

X4-7

X8-3

X4-3

X2-4

X4-1

X8-2

X2-2

X4-2

X4-9

X3-1

X3-2

X3-3

X3-4

X3-5
X1-5

X1-3

X1-2

X2-1

X2-5
DEVICE NET KSR

Latest revision: Lab/Office: Status: Plant: = SWCAE

REGION A & E SWC IRC5 M2004 +B
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: +
BOSCH AC/MFDC Document no. Rev. Ind Page 105
Next =SWC/1
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 SIGNAL 3HAC026208-001 07
Total 26
 1 2 3 4 5 6 7 8

Rx+/Tx+
Rx+/Tx+
SHIELD

Rx-/Tx-
Rx-/Tx-
CAN_H

CAN_L
24V

0V

0V
-A35.X2

-A39.X1
3 5 1 4 2 1 3 2 9 5

SINGLE
CABINET

2:WHOG

3:WHGN
1:WHBU
3HAC029444-001 3HAC029486-001

2:WH

2:OG

3:GN
1:RD

2:BU

1:BU
1:BK
-3HAB8277-1 -3HAC025999-001
AWG26
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

SPOT
WELDING
CABINET

-XT/XP5.2
9 10

Bare wire

2:WH
1:RD

2:BU
1:BK
-3HAB8277-1

X5

X5
-I/OB1

-I/OB2
3 5 1 4 2 3 5 1 4 2

2:WHOG
1:WHBU

2:OG
1:BU
-3HAC025999-001
SEE PAGE I/O SIGNALS SEE PAGE I/O SIGNALS

DEVICE NET DEVICE NET

=SWC+B-X2I =SWC+B-X2O
-VE101
=SWC+B-X2U

=SWC+B-X3C
BOSCH 5 3 4
COMPACT 3 2 1
1 11 14 13 12 3 4 5 6 7 8 9 10 11 9 10 5 7 8

GND 0V 0...10V

Latest revision: Lab/Office: Status: Plant: = SWC

REGION E SWC IRC5 M2004 +B
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: +
COMPACT BOSCH AC Document no. Rev. Ind Page 106
Next +S.B/10
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 TIMER SIGNAL 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

-V101 -I/OB1
X2I SPOT WELDING
CONNECTION BOX
X1 CABINET
-XT/XP5.1 3HAC029393-001 -XS/XP8.1
-3HAC2360-3
-682 AWG20 OG 1 AWG24
start1 1 1:WHBU SPARE
-683 AWG20 OG 2
weld/no weld, ext 11 1 11

-684 AWG20 OG 3
1:BU SPARE
fault reset 14
-710 2 12
-685 AWG20 4 AWG20
ackn. tip dress 13
OG OG 2:WH/OG gun_open
-686 AWG20 OG 5 -711 3 13
ackn. tip change 12 AWG20 OG 2:OG hlift_open
6
4 14
7
-XS/XP8.2
8

-707
AWG20 OG 3:WH/GN temp_ok
5 1 See page:
3:GN SPARE Customer
6 2
signal -
X2 -681
AWG20 OG 4:WH/BN equalize IRBDP SW5
temp ok 3
-688 7 3
1 AWG20
pressure ok 4
OG 4:BN close_gun
-693 AWG20 OG 2 -691 8 4
prog sel 1 5 AWG20 OG 5:WH/GY open_hlift
We reserve all rights in this document and in the information contained therein.Reproduction, use or

-694 AWG20 3
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

OG
prog sel 2 6 -692 9 5
4
AWG20 OG 5:GY close_hlift
-695 AWG20 OG
prog sel 4 7
10 6
-696 AWG20 OG 5
6:RD/BU SPARE
prog sel 8 8
11 7
-697 AWG20 6
prog sel 16 9
OG 6:BU SPARE
-698 AWG20 OG 7 -705 12 8
prog sel 32 10 AWG20 OG 7:RD/OG flow2_ok
8
-706 13 9
AWG20 OG 7:OG air_ok
14
X2O 10
X3 -XT/XP5.2 SPARE
-700
AWG20 OG 8:RD/GN
Weld complete 11
-701 1 1 11
AWG20 OG
Timer ready 9 8:GN SPARE
-702 2
AWG20 OG
Weld fault 10 2 12
-703 3
9:RD/BN SPARE
AWG20 OG
Tip dress req 5
3 13
4
Prewarning tip change 7
9:BN SPARE
5 4 14
End of life tip change 8
-XS/XP8.3
6

-707
10:RD/GY flow1_nok
AWG20 OG 7
-704 5 7
8
AWG20 OG 10:GY flow1_ok
-687 6 8
AWG20 OG 11:BK/BU start_water
-709 7 9
X4 AWG20 OG 11:BU pressure_ok See page:
-709
AWG20 OG
8 10 Water and
-3HAC025999-1 air unit
1 1:WHBU 12:BK/OG Press. output GND
2:WHOG
2 9 11

-712
1:BU 12:OG Press. output (0..10V)
AWG20 OG 3 2:OG 10 12

-713
13:BK/GN SPARE
AWG20 4 11 13
OG 13:GN SPARE
-714 12
AWG20 OG 5 -X2U 14
OPTION: TIMER
6 BOSCH
WELD CONTACT FOR FUTURE TO CONTACTOR COMPACT 3 2 1

Latest revision: Lab/Office: Status: Plant: = SWC

Region E SWC IRC5 M2004 +S
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: + B
COMPACT BOSCH AC Document no. Rev. Ind Page 107
Next =SWCAE
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 I/O SIGNALS 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

DIGITAL I/O UNIT

-I/OBOARD1 -700AWG20 BU SINGLE CABINET SPOT WELDING CABINET
-X3 -701AWG20 BU XS/XP60 CP/CS -XS/XP113
+.IN-703AWG20 BU AWG24 8:WHOG g1_weld_contact -XT5.5
IN 1

WATER AND AIR UNIT - SWC

35
1 9 B9
IN 2 +.RG-704AWG20 BU 7:WHVT g1_flow1_ok -1003 AWG18 OG

SEE PAGE: 113

2 3 B3 3
IN 4 +.RG-705AWG20 BU 7:VT g1_flow2_ok -1004 AWG18 OG

4 4 B4 4
IN 5 +.RG-706AWG20 BU 7:WHGY g1_air_ok -1005 AWG18 OG

5 8:WHBK g1_pressure_ok B5
-1007 AWG18 OG 5
5
IN 6 7 7:GY g1_start_water B7
-1006 AWG18 OG 7
6 10:WHYE Spare B6
-1011 AWG18 OG 6
6
IN 7 8:BK g1_weld_power B11 11
8 B8
7
8:OG TIMER ON
10 B10
IN 8 -3HAC15654-1 -XT5.4

SEE PAGE: 105, 106

Bosch AC/MFDC
8
1:WHBU 4:WHOG KSR -1009 AWG18 OG

21 F7

Medar AC
0 VDC 1:BU 4:OG KSR 9
22 F8
9
2:WHOG 5:WHYE VOLT REG. -1008 AWG18 OG

23 F5
2:OG 5:YE VOLT REG. 8
-1110AWG20 24 F6
INPUT CH 1-8 BU -1010 AWG18 OG

SEE PAGE: 100, 101

-X4 OPTION 873 Spare/Start tip dress -1096 /
-XS/XP61 10

Power supplay
+.RG-709AWG20 Spare/Mains on B12

OPTION 873
IN 9 BU -1094 /
11 10:YE Spare/Tip dress on B1
-1095 /
1
+.RG-710AWG20 12 B2
IN 10 BU 9:WHRD

1
We reserve all rights in this document and in the information contained therein.Reproduction, use or

9:RD
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

2
+.IN-700AWG20 2
IN 11 BU

-XT5.1 AWG24 -XS/XP13

3
0 VDC 16 OG g1_gun_open. Pneu/Spare

Bosch AC/MFDC
SEE PAGE: 105
9 4 B12
DSQC YE g1_hlift_open. Pneu/Spare
328 INPUT CH 9-16 +.RG-707AWG20 BU
5 B13
-X1 BU g1_temp_ok. Servo/Pneu
OUT 1 +.RG-681AWG20 BU
7 C19

1
GN g1_equalize. Servo/Pneu/Spare
OUT 2 +.RG-682AWG20 BU
6 B14

2
RD g1_close_gun. Pneu/Spare

SEE CIRCUIT DIAGRAM 3HA026209-001

OUT 6 +.RG-686AWG20 BU
3 B11

6
OUT 7 +.RG-687AWG20 BU AWG24
8 2/OG VOLT REG.

CABLE TO R1.CP/CS
2/OG
7
OUT 8 +.RG-688AWG20 BU
12 B10

8
2/WH 2/WH VOLT REG.
0 VDC +.RG-830AWG20 BU
11 B9

9
1/BU 1/BU KSR
24 VDC +.RG-831AWG20 BU
10 B8

10
1/WH 1/WH KSR
OUTPUT CH 1-8 9 B7
-X2 +.RG-691AWG20 BU BK g1_open_hlift. Pneu/Spare
OUT 9 1 B1
+.RG-692AWG20 BU BN g1_close_hlift. Pneu/Spare
1
OUT 10 2 B2
+.RG-698AWG20 BU
2
OUT 15 -XT6 AWG20
-XT31 +.RG-1088 AWG16 BU 24 BK 24V
7 3
OUT 16 1
BN
A1
7
+.RG-1089 AWG16 BU RD 0V
8
0 VDC 2
OG
A2
BU

BU

9
AWG16
AWG16

24 VDC 2
YE 24V
10 3 A3
6
BU 0V
OUTPUT CH 9-16
4 A4

Latest revision: Lab/Office: Status: Plant: = SWCAE

REGION A & E SWC IRC5 M2004 + RG
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: +
BOSCH AC/MFDC Document no. Rev. Ind Page 108
Next +PG/109
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 ROBOT GUN (RG) 3HAC026208-001 07
Total 26
 1 2 3 4 5 6 7 8

DIGITAL I/O UNIT

I/OBOARD1 SINGLE CABINET -X104 -SG.CP/CS PEDESTAL GUN
X3 -XS/XP60 CP/CS -XS/XP113 SPOT WELDING CABINET (CUST. CONN.)
IN 4 +.SG-703 AWG20 BU AWG24 8:WHOG -XT5.5
35
4 9 B9
IN 5 +.SG-704 AWG20 BU 7:WHVT -1003 AWG18 OG

WATER AND AIR UNIT - SWC

5 3 B3 3
IN 6 +.SG-705 AWG20 BU 7:VT -1004 AWG18 OG

SEE PAGE: 113

6 4 B4 4
IN 7 +.SG-706 AWG20 BU 7:WHGY -1005 AWG18 OG

7 5 B5 5
IN 8 8:WHBK -1007 AWG18 OG

8 7 B7 7
0 VDC 7:GY -1006 AWG18 OG

9 6 B6 6
10:WHYE -1011 AWG18 OG

INPUT CH 1-8 11
B11
X4 +.SG-709 -XT5.4

BOSCH AC/MFDC
IN 9 AWG20 -1009 AWG18

SEE PAGE: 105

BU OG

1
+.SG-710 9
IN 10 AWG20 BU 8:BK -1008 AWG18 OG

2
+.SG-711 8 B8 8
IN 11 AWG20 BU 8:OG -1010 AWG18 OG

10
3 10 B10
0 VDC -XT5.6 AWG24

-1015 AWG18 g1_open_hlift. Pneu/spare

We reserve all rights in this document and in the information contained therein.Reproduction, use or

1:WHBK OG 1:WHBK
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

9
13 C3 3 B18
INPUT CH 9-16 1:BK -1016 AWG18 OG 1:BK g1_close_hlift. Pneu/spare
14 C4 4 B19
6:WHGN -1017 AWG18 OG 6:WHGN g1_close_gun. Pneu/spare
15 C5 5 B1
6:GN -1018 AWG18 OG 6:GN g1_gun_open. Pneu/spare
DSQC 16 C6 6 B2
328 6:WHBU -1019 AWG18 OG 6:WHBU g1_hlift_open. Pneu/spare
X1 g1_equalize.
17 C7 7 B3
OUT 1 +.SG-681 AWG20 BU 6:BU -1020 AWG18 OG 6:BU Servo/Pneu/Spare
1 18 C8 8 B4
+.SG-707 AWG20 BU 9:BN -1021 AWG18 OG 9:BN g1_temp_ok. Servo/Pneu
19
C9 9 B14
OUT 6 +.SG-686 AWG20 BU -XS/XP61 2:WHBN -1022 AWG18 OG 2:WHBN SPARE
6 C10 10 B20
OUT 7 +.SG-687 AWG20 BU
11
2:BN -1023 AWG18 OG 2:BN SPARE
7 C11 11 B21
OUT 8 +.SG-688 AWG20 BU
5
9:WHBN -1024 AWG18 OG 3:WHRD SPARE
B22
8 C12 12
0 VDC +.SG-830 AWG20 BU
6
3:WHRD 3:RD

9 C1
24 VDC +.SG-831 AWG20 BU
7
3:RD / =SWC+-XT101_7 -1013 AWG18 OG 0,75 24VDC
10 C2 1 0,75 C4
3 / =SWC+-XT101_3 -1014 AWG18 OG 0,75 0VDC
OUTPUT CH 1-8 0,75
B1 2 C5
4
AWG16 GN/YE

X2 9:WHRD
B2
OUT 9 +.SG-691 AWG20 BU
1
9:RD B12 -VE101_X3 AWG24 -XS/XP5.7
1
OUT 10 +.SG-692 AWG20 BU
2 1
2 RD 4:WHOG KSR
BOSCH AC/MFDC
=SWCAE+PG-XS/XP113 1 B24
KSR
SEE PAGE: 105
10:YE BK 4:OG
2 2
12 2 B25
OUT 16 +.SG-698 AWG20 BU
AWG20
8
-XT31 4
BU 5:WHYE VOLT REG.
Robot Gun (RG)
SEE PAGE: 108

4 B16
0 VDC 7 5
5:YE VOLT REG.
5 B17
9 3
24 VDC 6 3
DRAIN SHIELD
WIRE 3
10 2

OUTPUT CH 9-16

Latest revision: Lab/Office: Status: Plant: = SWCAE

REGION A & E SWC IRC5 M2004 + PG
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: +
XT31.Terminal No. changed(3). BOSCH AC/MFDC Document no. Rev. Ind Page 109
Next =WA_AE
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 PEDESTAL GUN (PG) 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

/
/
=WA+--XT101_2
=WA+--XT101_6
DIGITAL I/O UNIT
-I/OBOARD1 SINGLE CABINET SPOT WELDING CABINET WATER AND AIR UNIT
DSQC DSQC
327A 328
-XS/XP113 -XT5.5 -XS/XP103 -XS/XP101
-3HAC16844
-1085 AWG18 OG -1043 AWG18 OG AWG18 WH 24V
-X3 1 1 19
IN 4 +.SG-703 AWG20 BU -XS/XP60 -1086 AWG18 OG -1044 AWG18 OG VT 0V
CP/CS 2 2 6
4
IN 5 +.SG-704 AWG20 BU AWG24 7:WHVT -1003 AWG18 OG -1045 AWG18 OG GY g1_flow1_ok
35
5 3 B3 3 3 5
IN 6 +.SG-705 AWG20 BU 7:VT -1004 AWG18 OG -1046 AWG18 OG WHBK g1_flow2_ok
6 4 B4 4 4 16
IN 7 +.SG-706 AWG20 BU 7:WHGY -1005 AWG18 OG -1047 AWG18 OG WHBN g1_air_ok
7 5 B5 5 5 3
0 VDC
9
INPUT CH 1-8 7:GY -1006 AWG18 OG -1048 AWG18 OG RD g1_start_water
-X4 +.SG-709 6 B6 6 6 15
IN 9 AWG20 BU 8:WHBK -1007 AWG18 OG -1049 AWG18 OG BK g1_pressure_ok. Pneu
1 7 B7 7 7 17
0 VDC -1011 AWG18 OG -1053 AWG18 OG BU PROP. REF. Pneu
9 11 8 9
OG SPARE
We reserve all rights in this document and in the information contained therein.Reproduction, use or

9 7
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

INPUT CH 9-16
Option: BN SPARE
-X1 +.SG-686 SEE PAGE: 105 10 14
OUT 6 AWG20 BU 8:BK -1008 AWG18 OG Bosch AC/MFDC YE SPARE / g1_epvalve_ok
6
+.SG-687 8 B8 11 2
OUT 7 AWG20 BU 8:WHOG -1009 AWG18 OG GN SPARE
7 9 B9 12 13
8:OG -1010 AWG18 OG AWG16 GN/YE

10 B10

+.SG-830 -XT31
0 VDC AWG20 BU 6
9
+.SG-831
24 VDC AWG20 BU -XT5.4

SEE PAGE: 105, 106

2

Bosch AC/MFDC
10

Medar AC
OUTPUT CH 1-8
-X2 +.SG-698 -XS/XP61 8
OUT 16 AWG20 BU SPARE 9:WHRD

8 1 B1 9
0 VDC SPARE 9:RD

9 2 B2 10
24 VDC SPARE 10:WHYE

SEE PAGE: 100, 101

10 11 B11
SPARE -1094

Power supplay
OUTPUT CH 9-16 10:YE /

OPTION 873
12 B12 -1095 /
SPARE 2:WHBN -1096 /
Robot gun (RG)
SEE PAGE: 109
OPTION 873

/ -700 5 C10
/ -701 SPARE 2:BN

/ -1110 6 C11
/ -682 SPARE 9:WHBN

7 C12
SPARE 3:WHRD

3 C1
SPARE 3:RD

4 C2
AWG16 GNYE

=WA_AE+SWC-XS/XP113

Latest revision: Lab/Office: Status: Plant: = WA_AE

REGION A & E SWC IRC5 M2004 + SWC
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: +
XT31.Terminal No. changed(2). BOSCH AC/MFDC Document no. Rev. Ind Page 110
Next +SB/111
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 WATER AND AIR UNIT - SWC 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

-SPLITBOX1
-XS/XP101 -XS/XP101.1 -XS/XP101.1
MECHANICAL OPTION: DIGITAL
24 VDC /112.2
1 1
19
0 VDC 2
0V -VD101.1 WATER 2
0V -VD101.1 WATER
3 1 2 VALVE 3 1 2 VALVE
6 SIGNAL SIGNAL
g1_flow1_ok 4 4
5 5
5
g1_flow2_ok
16
g1_air_ok -XS/XP101.2 -XS/XP101.2
3
24V 24V
1 1
2 2
g1_start_water 0V 0V
3 BU 3 BU
15
SPARE / g1_pressure_ok FLOW OPTION:
17 SIGNAL BK BN CONTROL 1 SIGNAL BK BN FLOW
4 4 CONTROL 1
SPARE / PROP. REF. SIGNAL WH
5 5
9
SPARE -SF101.2 -SF101.2
7 -XS/XP101.3 -XS/XP101.3
SPARE
14 24V 24V
1 1
We reserve all rights in this document and in the information contained therein.Reproduction, use or

SPARE
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

2 2
2 0V 0V
SPARE 3 BU 3 BU
13 OPTION: OPTION:
SIGNAL BK BN FLOW SIGNAL BK BN FLOW
4 CONTROL 2 4 CONTROL 2
SIGNAL WH
5 5
(1*)
-SF101.3 -SF101.3
VALID FOR -XS/XP101.4

3HAC16711-1 24V
3HAC16711-2 1
SIGNAL
3HAC16711-3 2
0V
3HAC16711-4 3 BU WH
3HAC16711-5 OPTION:
3HAC16711-6 PRESSURE
SIGNAL BK BN
3HAC16711-7 4 SWITCH
3HAC16711-8 5
3HAC16711-9 (1*)
3HAC16711-10 -SF101.4
3HAC16711-11 -XS/XP101.5
3HAC16711-12
24V
1
PROP. REG.
2
0V OPTION:
3 PROP. VALVE 1
FEED BACK
4 PNEU.
5
-PV1
(1*)

-XS/XP101.6

1
2
3
4
5

(1*) TERMINAL 1 AND 4 STRAPPED IF NOT USED.

Latest revision: Lab/Office: Status: Plant: = WA_AE

REGION A & E SWC IRC5 M2004 + SB
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: +
BOSCH AC/MFDC Document no. Rev. Ind Page 111
Next 112
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 WATER AND AIR UNIT - SPLIT BOX 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

-SPLITBOX2
-XS/XP101 -J1
MECHANICAL
24 VDC /111.2
1
19
0 VDC 2
0V -VD101.1 WATER
3 1 2 VALVE
6 SIGNAL
g1_flow1_ok 4
5
5
g1_flow2_ok
16
g1_air_ok -J2
3
24V
1
2
g1_start_water 0V
3 BU
15
SPARE / g1_pressure_ok FLOW
17 SIGNAL BK BN CONTROL 1
4
SPARE / PROP. REF. SIGNAL WH
5
9
SPARE -SF101.2
7 -J3
SPARE
14 24V
1
We reserve all rights in this document and in the information contained therein.Reproduction, use or

g1_epvalve_ok
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

2
2 0V
SPARE 3 BU
13 OPTION:
SIGNAL BK BN FLOW
4 CONTROL 2
SIGNAL WH
5
(1*)
-SF101.3
VALID FOR -J4

3HAC027294-001 24V
3HAC027294-002 1
SIGNAL
3HAC027294-003 2
0V
3 BU WH
PRESSURE
SIGNAL BK BN SWITCH
4
5

-SF101.4
-J5

24V
1
PROP. REG.
2
0V OPTION:
3 PROP. VALVE 1
FEED BACK
4 PNEU.
5
-PV1

-J6

1
2
3
4
5

(1*) TERMINAL 1 AND 4 STRAPPED IF NOT USED.

Latest revision: Lab/Office: Status: Plant: = WA_AE

REGION A & E SWC IRC5 M2004 + SB
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: +
BOSCH AC/MFDC Document no. Rev. Ind Page 112
Next =WA+S/
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 WATER AND AIR UNIT - SPLIT BOX 3HAC026208-001 07 Total 26
 1 2 3 4 5 6 7 8

-XS/XP8.3 MECHANICAL

24 VDC
1
0 VDC 0V
4
EARTH -VD101 WATER
1 2 VALVE
SIGNAL

24V

g1_flow1_nok SIGNAL WH FLOW

7 CONTROL 1
g1_flow1_ok SIGNAL BK BN
8
g1_start_water
9 -SF101
g1_pressure_ok
10
We reserve all rights in this document and in the information contained therein.Reproduction, use or

OPTION: 796-1
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

Pressure output GND 24V BN 1

PROP. VALVE 1
11 PNEU.
Pressure outpt (0...10V) INPUT WH 2
12
SPARE OUTPUT BK 4
13
EARTH GND BU 3
14
-PV1

DELIVERED BY SMC

Latest revision: Lab/Office: Status: Plant: = WA

REGION E SWC IRC5 M2004 +S
Rev. 07 Location:
CM 500000056877
APPROVED Sublocation: +
COMPACT BOSCH AC Document no. Rev. Ind Page 113
Next
Prepared by, date: THSTA, 2013-05-08 Approved by, date: MATO, 2013-05-08 WATER AND AIR UNIT 3HAC026208-001 07 Total 26