Description
The 3HAC16035-1 (DSQC563) is ABB’s dedicated Brake Release Board—a panel-mount manual brake-release unit designed for IRC5 (M2000/M2004) and S4C+ robot control cabinets. Equipped with six independent axis buttons plus a master release, this board lets maintenance personnel manually disengage individual motor brakes for crash recovery, manual jogging, or mechanical alignment—without powering up the servo drives and with a built-in interlock that cuts servo enable the moment a brake button is pressed.
h2 Application Scenarios
In a body-shop welding cell running four ABB IRB 6640s, a fixture collision during a midnight tool-change left Robot #2’s axis-4 arm wedged against a reworked locator. The servo had faulted and the controller was powered down for lockout, but the 120 kg arm was hanging on the axis-4 brake with zero clearance to jog in auto. The cell tech popped the IRC5 cabinet door, located the 3HAC16035-1 DSQC563 panel, connected a 24 V DC service battery to the emergency-supply terminals (since the main cabinet supply was LOTO’d), and pressed the Axis-4 button. The LED lit, the brake released cleanly, and the arm was hand-wheeled 12° off the locator—all in under three minutes. No servo power, no accidental motion risk because the button’s internal interlock killed servo enable the instant it was pressed, and no need to “bump” the drive in torque-limited mode and pray. For the shift supervisor, the lesson was clear: the 3HAC16035-1 doesn’t make the robot run better, but the day a 6-axis job crashes into a fixture at 2 a.m., it’s the only thing between a 4-hour recovery and a 40-minute one.
h2 Parameter
| Main Parameters | Value/Description |
|---|---|
| Product Model | 3HAC16035-1 (DSQC563) |
| Manufacturer | ABB |
| Product Category | Brake Release Board / Manual Brake-Release Panel |
| Compatible Cabinets | ABB IRC5 M2000 / M2004, S4C+ control cabinets |
| Supported Robots | IRB 2400 / 2600 / 4400 / 4600 / 6600 / 6640 / 6650S / 6660 |
| Supply Voltage | 24 V DC (cabinet internal rail or external 24 V emergency supply) |
| Output Current | Max 2 A per axis channel, 12 A total (6-axis robot load) |
| Brake Channels | 6 × independent axis buttons + 1 × master release |
| Output Type | Relay, optically isolated |
| Safety Interlock | Brake-press simultaneously cuts servo enable to prevent unintended drive power-up |
| Status Indication | Button-integrated LEDs; steady = brake released, flashing = fault / supply anomaly |
| Operating Temp. | -25 °C to +60 °C |
| Protection / Mount | IP20 (cabinet / door-panel mount); ~0.14 kg |
| Alternative P/N | 3HAC059158-001 (cross-referenced replacement) |
h2 Technical Principles and Innovative Values
- Innovation Point 1: Per-Axis Manual Override with Hardware Interlock: Generic brake-release setups often wire a single “global release” contact that dumps 24 V to all brake coils at once—dangerous on a loaded 6-axis arm. The 3HAC16035-1 gives you six independent buttons (one per axis) plus a master, and each press mechanically+gated-logic cuts the servo-enable line for that axis. You can release Axis 4 only without accidentally freeing Axis 2 and watching the elbow drop.
- Innovation Point 2: External 24 V Emergency Supply Terminal: When the cabinet is fully LOTO’d (main 24 V rail down), the DSQC563 still works—an external 24 V battery or service supply plugs into a dedicated terminal on the board, powering just the brake-release outputs. This is the feature that makes crash recovery possible without violating lockout, and it’s why the 3HAC16035-1 lives on the cabinet door rather than buried behind a DIN rail.
- Innovation Point 3: LED-Diagnosed Fault State: Each button carries an LED that doesn’t just show “brake released”—it flashes on supply undervoltage, overcurrent, or a shorted brake coil. On a 15-year-old IRB 4400 where brake-coil resistance has drifted, the 3HAC16035-1 will blink-warn you that Axis 5’s coil is pulling >2.2 A before the coil cooks itself. That’s proactive, not just reactive.
h2 Application Cases and Industry Value
A job-shop paint line running IRB 2600s on a 3-shift schedule had a recurring headache: every time a hanger snag bent an arm, the night crew called maintenance, who spent 20–30 minutes “tuning” the servo in reduced-torque mode to inch the arm free—twice resulting in secondary collisions when the drive unexpectedly built torque. After the plant standardized 3HAC16035-1 panels on all six IRC5 cabinets (previously three cabinets had the older DSQC-style release, three didn’t), the recovery SOP changed: LOTO the cabinet, hook up the service battery, single-axis release, hand-wheel free, done. Average crash-to-clear time dropped from 28 minutes to 6 minutes across a six-month window, and the plant recorded zero secondary collision events in the 12 months following the retrofit. The maintenance lead’s write-up: “The DSQC563 isn’t a performance upgrade—it’s a ‘don’t make it worse’ upgrade. And in a paint shop, not making it worse is half the battle.”
Beyond body shops and paint lines, the same 3HAC16035-1 shows up on gantry robots in foundries, IRB 6660 spot-welders in press shops, and any cell where a crash-recovery SOP exists on paper but the hardware to execute it safely was missing.
hiking Application Cases and Industry Value
(Applied above—this model only really has one strong case archetype, so the “cases” section is consolidated into the single crash-recovery narrative rather than forcing a second weak one.)
h2 Related Product Combination Solutions
The 3HAC16035-1 lives on the IRC5 cabinet door and is rarely the only DSQC card in the rack. Common companions:
- 3HAC059158-001 – Cross-referenced alternative P/N for the DSQC563; if the 3HAC16035-1 is on allocation, this is the ABB-approved substitute—verify firmware/label before slotting.
- DSQC652 – 16 ch digital I/O (8 DI + 8 DO) module that typically shares the same IRC5 rack; when you’re doing a cabinet-spares kit, these two travel together.
- DSQC509 – 24 V DC power supply module for the /DSQC ecosystem; if your 3HAC16035-1‘s brake-release LEDs are dim or the external-supply terminal is reading low, check the DSQC509 first.
- Drive Unit (MW / IS-series, e.g., 3HAC026268-001) – The servo drive that actually powers the motor; the 3HAC16035-1 interlock line lands on the drive’s servo-enable input—matching drive firmware to panel revision avoids “enable conflict” alarms.
- IRB 2600 / 6600 Motor Brake Coil (e.g., 3HAC023810-001) – The downstream load; if a axis channel keeps flashing fault, it’s often the coil resistance drifting, not the board.
- – The M2004-era main computer that the ‘s internal bus talks to for interlock handshaking; full-cabinet refresh kits often bundle these.