ABB IRC5 M2004 FlexPendant Operator’s manual

Operator’s manual

FlexPendant

IRC5

M2004

Operator’s manual

IRC5 with FlexPendant

M2004

Document ID: 3HAC 16590-1

Revision: B

The information in this manual 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 manual.

Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.

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

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

© Copyright 2005 ABB All right reserved.

ABB Automation Technologies AB

Robotics

SE-721 68 Västerås

Sweden

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Safety 13

1.1 About the Safety chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2 Applicable safety standards for IRC5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.3 Safety terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.3.2 DANGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.3.2.1 DANGER - Make sure that the main power has been switched off! . . . . . . . . . . . . . . . . 17

1.3.2.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.3.2.3 DANGER - Manipulator without axes’ holding brakes are potentially lethal! . . . . . . . . . 19

1.3.3 WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.3.3.1 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.3.4 What is an emergency stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.3.5 What is a safety stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.3.6 What is safeguarding? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.3.7 Enabling device and hold-to-run buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.4 How to deal with an emergency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.4.1 Stop the system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.4.2 Release the robot holding brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.4.3 Extinguishing fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.4.4 Recover from emergency stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.4.5 Return to the programmed path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.5 Working in a safe manner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.5.2 For your own safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.5.3 Handling of FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.5.4 Safety tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.5.5 Safety in manual reduced speed and manual full speed mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1.5.6 Safety in automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2 Welcome to FlexPendant 37

2.1 About the Welcome to FlexPendant chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.2 What is a FlexPendant? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.3 What is an IRC5 controller? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.4 What is RobotStudio Online? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

2.5 When to use the FlexPendant and RobotStudio Online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.6 Buttons on the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3 Get started 49

3.1 About the Get started chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.2.1 Connecting a FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.2.2 Disconnecting a FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.2.3 Connecting a PC to the service port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.2.4 Set up the network connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.3 Action scenarios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.3.1 About the Action Scenarios chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3.3.2 System start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.3.3 Jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3.3.4 Using RAPID programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.3.5 Working with inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3

Table of Contents

3.3.6 Backup and restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3.3.7 Running in production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3.3.8 Granting access for RobotStudio Online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.3.9 Upgrading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3.3.10 Installing software options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.3.11 Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3.3.12 General procedure when trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

4 Navigating and handling FlexPendant 71

4.1 About the Navigate and handle FlexPendant chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.2 Overview, personalizing the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.3 The ABB menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.3.1 HotEdit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.3.2 FlexPendant Explorer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4.3.3 Inputs and outputs, I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4.3.4 Jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.3.5 Production window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.3.6 Program data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

4.3.7 Program editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4.3.8 Backup and restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4.3.9 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4.3.10 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

4.3.11 Event log menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

4.3.12 Lock the screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

4.3.13 System info. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

4.3.14 Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

4.3.15 Logout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

4.4 The status bar menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

4.4.1 Operator window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

4.4.2 Status bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

4.5 The QuickSet menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

4.5.1 The Quickset menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

4.6 Basic procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.6.1 Using the soft keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

4.6.2 Messages on the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

4.6.3 Scrolling and zooming on the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4.6.4 Filtering data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

4.6.5 Process applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

4.6.6 How to logout and login. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

5 Jogging 105

5.1 Introduction to jogging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

5.2 Jogging concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

5.2.1 Restrictions to jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

5.2.2 Coordinated jogging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

5.3 Basic settings for jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

5.3.1 Selecting mechanical unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

5.3.2 Selecting motion mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

5.3.3 Selecting tool, work object, and payload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

5.3.4 Setting the tool orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

5.3.5 Jog axis by axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

5.3.6 Jog in base coordinates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

5.3.7 Jog in world coordinates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

4

Table of Contents

5.3.8 Jog in work object coordinates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

5.3.9 Jog in tool coordinates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

5.3.10 Locking the joystick in specific directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

5.3.11 Incremental movement for precise positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

5.3.12 How to read the exact position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

5.3.13 Quickset menu, Mechanical unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

5.3.14 Quickset menu, Increment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

6 Programming and testing 133

6.1 Before you start programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

6.2 Programming concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

6.2.1 The structure of a RAPID application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

6.3 Data types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

6.3.1 Viewing data in specific tasks, modules, or routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

6.3.2 Creating new data instance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

6.3.3 Editing data instances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

6.4 Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

6.4.1 Creating a tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

6.4.2 Defining the tool frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

6.4.3 Editing the tool data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

6.4.4 Editing the tool declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

6.4.5 Deleting a tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

6.4.6 Setup for stationary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

6.5 Work objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

6.5.1 Creating a work object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

6.5.2 Defining the work object coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

6.5.3 Editing the work object data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

6.5.4 Editing the work object declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

6.5.5 Deleting a work object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

6.6 Payloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

6.6.1 Creating a payload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

6.6.2 Editing the payload data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

6.6.3 Editing the payload declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

6.6.4 Deleting a payload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

6.7 Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

6.7.1 Handling of programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

6.7.2 Handling of modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

6.7.3 Handling of routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

6.7.4 Handling of instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

6.7.5 Example: Add movement instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

6.8 Advanced programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

6.8.1 Mirroring a program, module, or routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

6.8.2 Modifying positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

6.8.3 Moving the robot to a programmed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

6.8.4 Aligning tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

6.8.5 Editing instruction expressions and declarations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

6.8.6 Hiding declarations in program code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

6.8.7 Deleting programs from memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

6.8.8 Deleting programs from hard disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

6.8.9 Activating mechanical units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

6.9 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

6.9.1 How to use the hold-to-run function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

6.9.2 Running the program from a specific instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

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Table of Contents

6.9.3 Running a specific routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

6.9.4 Quickset menu, Run Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

6.9.5 Quickset menu, Step Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

6.9.6 Stepping instruction by instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

6.9.7 Quickset menu, Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

6.10 Service routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

6.10.1 Running a service routine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

6.10.2 Battery shutdown service routine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

6.10.3 Calibration Pendulum, CalPendulum service routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

6.10.4 Service Information System, ServiceInfo service routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

6.10.5 LoadIdentify, load identifiction service routine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

7 Running in production 219

7.1 Starting programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

7.2 Stopping programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

7.3 Using multitasking programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

7.4 Returning the robot to the path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

7.5 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

7.5.1 Present operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

7.5.2 About the automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

7.5.3 About the manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

7.5.4 Start up in automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

7.5.5 Start up in manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

7.5.6 Running programs in automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

7.5.7 Running programs in manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

7.5.8 Switching from manual to automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

7.5.9 Switching from automatic to manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

7.5.10 Switching to manual full speed mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

8 Handling inputs and outputs, I/O 237

8.1 Inputs and Outputs, I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

8.2 Simulating and changing signal values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

8.3 Viewing signal group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

8.4 Safety I/O signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

9 Handling the event log 243

9.1 Accessing the event log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

9.2 Deleting log entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

9.3 Saving log entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

10 Systems 247

10.1 About systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

10.2 Memory and file handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

10.2.1 What is “the memory”? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

10.2.2 The structure of the main computer RAM memory contents . . . . . . . . . . . . . . . . . . . . . . . . . . 249

10.2.3 File handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

10.3 Restart procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

10.3.1 Restart overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

10.3.2 Using the boot application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

10.3.3 Restart and use the current system (warm start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

10.3.4 Restart and select another system (X-start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

10.3.5 Restart and delete the current system (C-start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

10.3.6 Restart and delete programs and modules (P-start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

10.3.7 Restart and return to default settings (I-start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

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Table of Contents

10.3.8 Restart from previously stored system data (B-start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

10.3.9 Reflashing firmware and FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

10.4 Backup and restore systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

10.4.1 What is saved on backup? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

10.4.2 Backup the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

10.4.3 Restore the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

10.4.4 Important when performing backups! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

10.5 Configuring systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

10.5.1 Configuring system parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

11 Calibrating 273

11.1 How to check if the robot needs calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

11.2 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

11.3 Loading calibration data using the FlexPendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

11.4 Editing motor calibration offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

11.5 Fine calibration procedure on FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

11.6 Serial Measurement Board memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

11.7 4 points XZ calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

12 Changing FlexPendant settings 285

12.1 Changing brightness and contrast. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

12.2 Switching between left and right handheld FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

12.3 Changing date and time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

12.4 Configuring Most Common I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

12.5 Changing language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

12.6 Editing programmable keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

12.7 Editing supervision settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

12.8 Configuring view settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

12.9 Changing background image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

12.10 Calibrating the touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

13 Descriptions of terms and concepts 299

13.1 About the Descriptions of terms and concepts chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

13.2 What is the robot system?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

13.3 What are robots, manipulators and positioners?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

13.4 What is a tool? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

13.5 What is the tool center point? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

13.6 What is a work object? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

13.7 What is a coordinate system? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

13.8 What is a RAPID application? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

13.9 What is a data array? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

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8

Table of Contents

Overview

Overview

About this manual

This manual contains instructions for daily operation of IRC5 based robot systems using a

FlexPendant.

Usage

This manual should be used during operation.

Who should read this manual?

This manual is intended for:

• operators

• product technicans

• service technicans

• robot programmers

How to read the operator’s manual

The operator’s manual is structured in the following chapters.

5

6

Chapter Title

1

2

3

4

7

8

9

10

11

12

13

Content

Safety

Get started

Safety instructions and warnings.

Welcome to FlexPendant Descriptions of the FlexPendant and the

FlexController.

Descriptions of connections and step-by-step instructions to the most common tasks

Navigating and handling the FlexPendant

Jogging

Descriptions of the FlexPendant’s user interface and basic procedures.

Procedures for jogging.

Programming and testing Procedures for programming and testing, including descriptions of some concepts for programming.

Running in production

Handling inputs and outputs, I/O

Procedures for running in production.

Procedures for handling I/O.

Handling the event log

Systems

Calibrating

Changing FlexPendant settings

Descriptions of terms and concepts

Procedures for the event log.

Procedures for restart, backup, restore, and configuring systems.

Procedures for calibrating the robot system.

Procedures for changing the settings for the

FlexPendant.

Descriptions of terms and concepts used in robotics.

3HAC 16590-1 Revision: B

Continues on next page

9

Overview

Continued

Prerequisites

The reader should:

• be familiar with the concepts described in Getting started - IRC5 and RobotStudio

Online.

• be trained in robot operation.

References

Reference

Product manual, procedures - IRC5

Product manual, references - IRC5

Getting started - IRC5 and RobotStudio Online

Operator’s manual - RobotStudio Online

Trouble shooting manual - IRC5

Technical reference manual - System parameters

RAPID reference manual - RAPID overview

RAPID reference manual - Instructions

RAPID reference manual - Functions and data types

RAPID reference manaul - RAPID kernel

Application manual - Additional axes

Application manual - Engineering tools

Application manual - Motion coordination and supervision

Application manual - Motion functions and events

Application manual - MultiMove

Calibration pendulum instruction

Instructions for levelmeter calibration

Document ID

3HAC 021313-001

3HAC 021313-001

3HAC 021564-001

3HAC 18236-1

3HAC 020738-001

3HAC 17076-1

3HAC 16580-1

3HAC 16581-1

3HAC 16581-1

3HAC 16585-1

3HAC 021395-001

3HAC 020434-001

3HAC 18154-1

3HAC 18152-1

3HAC 021272-001

3HAC 16578-1

3HAC 022907-001

Revisions

Revision Description

-

A

B

First issued. IRC5 M2004. Released with RobotWare 5.04.

Second edition. Released with RobotWare 5.05.

Third edition. Released with RobotWare 5.06.

Organization of chapters restructured to task orientation.

10 3HAC 16590-1 Revision: B

Product documentation, M2004

Product documentation, M2004

General

The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain

all documents listed, only the ones pertaining to the equipment delivered.

However, all documents listed may be ordered from ABB. The documents listed are valid for

M2004 robot systems.

Hardware manuals

All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts:

Product manual, procedures

•

Safety information

• Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software)

•

Maintenance (descriptions of all required preventive maintenance procedures including intervals)

• Repair (descriptions of all recommended repair procedures including spare parts)

•

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

•

Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards)

• Part list

•

Foldouts or exploded views

• Circuit diagrams

RobotWare manuals

The following manuals describe the robot software in general and contain relevant reference information:

•

RAPID Overview: An overview of the RAPID programming language.

•

RAPID reference manual part 1: Description of all RAPID instructions.

• RAPID reference manual part 2: Description of all RAPID functions and data types.

• Technical reference manual - System parameters: Description of system parameters and configuration workflows.

3HAC 16590-1 Revision: B

Continues on next page

11

Product documentation, M2004

Continued

Application manuals

Specific applications (e.g. software or hardware options) are described in Application

manuals. An application manual can describe one or several applications.

An application manual generally contains information about:

• The purpose of the application (what it does and when it is useful)

• What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)

• How to use the application

•

Examples of how to use the application

Operator’s manuals

This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters. The group of manuals include:

•

Getting started - IRC5 and RobotStudio Online

•

Operator’s manual - IRC5 with FlexPendant

•

Operator’s manual - RobotStudio Online

•

Trouble shooting manual for the controller and robot

12 3HAC 16590-1 Revision: B

1 Safety

1.1. About the Safety chapter

1 Safety

1.1. About the Safety chapter

Introduction to safety

This chapter describes safety principles and procedures to be used when a robot or robot system is operated.

It does not cover how to design for safety nor how to install safety related equipment. These topics are covered in the Product Manuals supplied with the robot system.

3HAC 16590-1 Revision: B 13

1 Safety

1.2. Applicable safety standards for IRC5

1.2. Applicable safety standards for IRC5

Health and safety standards

The robot complies fully with the health and safety standards specified in the EEC’s

Machinery Directives.

The ABB robots controlled by the IRC5 conforms to the following standards:

Standard

EN ISO 12100-1

EN ISO 12100-2

EN 954-1

EN 775

EN 60204

EN 61000-6-4 (option)

EN 61000-6-2

Description

Safety of machinery, terminology

Safety of machinery, technical specifications

Safety of machinery, safety related parts of control systems

Manipulating industrial robots, safety

Electrical equipment of industrial machines

EMC, generic emission

EMC, generic immunity

Standard

IEC 204-1

IEC 529

Standard

ISO 10218

ISO 9787

Description

Electrical equipment of industrial machines

Degrees of protection provided by enclosures

Description

Manipulating industrial robots, safety

Manipulating industrial robots, coordinate systems and motions

Standard

ANSI/RIA 15.06/1999

ANSI/UL 1740-1998

(option)

CAN/CSA Z 434-03

(option)

Description

Safety requirements for industrial robots and robot systems

Safety standard for robots and robot equipment

Industrial robots and robot systems - General safety requirements

14 3HAC 16590-1 Revision: B

1 Safety

1.3.1. Safety signals, general

1.3 Safety terminology

1.3.1. Safety signals, general

General

This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of:

•

A caption specifying the danger level (DANGER, WARNING or CAUTION) and the type of danger.

• A brief description of what will happen if the operator/service personnel do not eliminate the danger.

•

An instruction of how to eliminate the danger to facilitate performing the activity at hand.

Danger levels

The table below defines the captions specifying the danger levels used throughout this manual.

Symbol

danger warning

Designation

DANGER

WARNING

ELECTRICAL

SHOCK

Signification

Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc.

Warns that an accident may occur if the instructions are not followed, that can lead to serious injury, possibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc.

The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personal injury or death.

Electrical shock

CAUTION caution

3HAC 16590-1 Revision: B

Warns that an accident may occur if the instructions are not followed, that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment, where there is a risk of damaging the product or causing a breakdown.

Continues on next page

15

1 Safety

1.3.1. Safety signals, general

Continued

Symbol Designation Signification

ELECTROSTATIC

DISCHARGE (ESD)

The electrostatic discharge (ESD) symbol indicates electrostatic hazards which could result in severe damage to the product.

Electrostatic discharge

(ESD)

NOTE Note symbols alert you to important facts and conditions.

Note

TIP Tip symbols direct you to specific instructions, where to find additional information or how to perform a certain operation in an easier way.

Tip

16 3HAC 16590-1 Revision: B

1 Safety

1.3.2.1. DANGER - Make sure that the main power has been switched off!

1.3.2. DANGER

1.3.2.1. DANGER - Make sure that the main power has been switched off!

Description

Working with high voltage is potentially lethal. Persons subjected to high voltage may suffer cardiac arrest, burn injuries or other severe injuries. To avoid these dangers, do not proceed working before eliminating the danger as detailed below.

Elimination

Step Action

1.

Switch off the main switch on the Control

Module.

Info/Illustration

2.

Switch off the main switch on the Drive

Module.

xx0400000978

• A: main switch, control module en0400001017

• A: main switch, drive module

3HAC 16590-1 Revision: B 17

1 Safety

1.3.2.2. DANGER - Moving manipulators are potentially lethal!

1.3.2.2. DANGER - Moving manipulators are potentially lethal!

Description

Any moving manipulator is a potentially lethal machine.

When running the manipulator, it may perform unexpected and sometimes irrational movements. However, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the manipulator working range.

Elimination

Step Action Info/Illustration

1.

Before attempting to run the manipulator, make sure all emergency stop equipment is correctly installed and connected.

Emergency stop equipment such as gates, tread mats, light curtains, etc.

2.

If possible, use the hold-to-run button whenever possible.

The hold-to-run button is used in manual mode, not in automatic mode.

3.

Make sure no personnel are present within the manipulator working range before pressing the start button.

How to use the hold-to-run function is

detailed in section

How to use the hold-to-run function on page 196

.

18 3HAC 16590-1 Revision: B

1 Safety

1.3.2.3. DANGER - Manipulator without axes’ holding brakes are potentially lethal!

1.3.2.3. DANGER - Manipulator without axes’ holding brakes are potentially lethal!

Description

Since the manipulator arm system is quite heavy, especially on larger manipulator models, it is dangerous if the holding brakes are disconnected, faulty, worn or in any way rendered nonoperational.

For instance, a collapsing IRB 7600 arm system may kill or seriously injure a person standing beneath it.

Elimination

Step Action Info/illustration

1.

If you suspect that the holding brakes are nonoperational, secure the manipulator arm system by some other means before working on it.

Weight specifications etc. may be found in the Product

Manual of each manipulator model.

2.

If you intentionally render the holding brakes nonoperational by connecting an external voltage supply, the utmost care must be taken!

NEVER stand inside the manipulator working area when disabling the holding brakes unless the arm system is supported by some other means!

How to correctly connect an external voltage supply is detailed in the Product

Manual of each manipulator model.

3HAC 16590-1 Revision: B 19

1 Safety

1.3.3.1. WARNING - The unit is sensitive to ESD!

1.3.3. WARNING

1.3.3.1. WARNING - The unit is sensitive to ESD!

Description

ESD (electro static discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges. This discharge may destroy sensitive electronics.

Elimination

Step Action Note/Illustration

1.

Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly.

2.

Use an ESD protective floor mat.

The mat must be grounded through a currentlimiting resistor.

3.

Use a dissipative table mat.

The mat should provide a controlled discharge of static voltages and must be grounded.

Location of wrist strap button

The wrist strap button is located on the computer unit in the control module as shown in the illustration below.

A

20 xx0400001061

A wrist strap button

Continues on next page

3HAC 16590-1 Revision: B

1 Safety

1.3.3.1. WARNING - The unit is sensitive to ESD!

Continued

Assemble the wrist strap

The picture illustrates how the ESD wrist strap is assembled in the controller.

xx0400001055

A

B

C

The strap is fastened to a button on the side of the control module.

When not used, the wrist strap is placed on the power supply unit.

Power supply unit

3HAC 16590-1 Revision: B 21

1 Safety

1.3.4. What is an emergency stop?

1.3.4. What is an emergency stop?

Definition of emergency stop

An emergency stop is a state that overrides any other robot control, disconnects drive power from the robot’s motors, stops all moving parts and disconnects power from any potentially dangerous functions controlled by the robot system.

An emergency stop state means that all power is disconnected from the robot except for the manual brake release circuits. You must perform a recovery procedure in order to return to normal operation.

The robot system can be configured so that the state results in either:

• an uncontrolled stop, immediately stopping the robot’s action by disconnecting power from its motors

• a controlled stop, stopping the robot’s action with power available to its motors so that the robot path can be maintained. When completed, power is disconnected.

Controlled stops are preferred since it minimizes the actions needed to return the robot system back to production. Please consult your plant or cell documentation to see how your robot system is configured.

Classification of stops

The safety standards that regulates automation and robot equipment defines categories in which each type of stop applies:

If the stop is...

uncontrolled controlled

..then it is classified as...

category 0 (zero) category 1

Emergency stop devices

In a robot system there are several emergency stop devices that can be operated in order to achieve an emergency stop. There are emergency stop buttons available on the FlexPendant and on the control module. There can also be other types of emergency stops on your robot, consult your plant or cell documentation to see how your robot system is configured.

22 3HAC 16590-1 Revision: B

1 Safety

1.3.5. What is a safety stop?

1.3.5. What is a safety stop?

Definition of safety stops

An emergency stop is a state that overrides any other robot control, disconnects drive power from the robot’s motors, stops all moving parts and disconnects power from any potentially dangerous functions controlled by the robot system.

A safety stop means that only the power to the robot’s motors is disconnected. There is no recovery procedure. You need only to restore motor power to recover from a safety stop.

The robot system can be configured so that the state results in either:

• an uncontrolled stop, immediately stopping the robot’s action by disconnecting power from its motors

• a controlled stop, stopping the robot’s action with power available to its motors so that the robot path can be maintained. When completed, power is disconnected.

Controlled stops are preferred since it minimizes the actions needed to return the robot system back to production. Please consult your plant or cell documentation to see how your robot system is configured.

Classification of stops

The safety standards that regulates automation and robot equipment defines categories in which each type of stop applies:

If the stop is...

uncontrolled controlled

..then it is classified as...

category 0 (zero) category 1

3HAC 16590-1 Revision: B 23

1 Safety

1.3.6. What is safeguarding?

1.3.6. What is safeguarding?

Definition

Safeguarding are safety measures consisting of the use of safeguards to protect persons from hazards which cannot reasonably be removed or sufficiently eliminated by design.

A safeguard prevents hazardous situations by stopping the robot in a controlled manner when a certain safeguarding mechanism such as a light curtain is activated.

Safeguarded space

The safeguarded space is the space guarded by the guards. For example, a robot cell is safeguarded by the cell door and its interlocking device.

Interlocking devices

Each present guard has an interlocking device which, when activated stops the robot. The robot cell door has an interlock that stops the robot when the door is opened. The only way to resume operation is to close the door.

Safeguarding mechanisms

A safeguarding mechanism consists of a number of guards connected in series. When a guard is activated, the chain is broken and the machine operation is stopped regardless of the state of the guards in the rest of the chain.

24 3HAC 16590-1 Revision: B

1 Safety

1.3.7. Enabling device and hold-to-run buttons

1.3.7. Enabling device and hold-to-run buttons

Enabling device

The enabling device is a manually operated constant pressure push-button which, when continuously activated in one position only, allows potentially hazardous functions but does not initiate them. In any other position, hazardous functions are stopped safely.

The enabling device is of a specific type where you must press the push-button only half-way to activate it. In the fully in and fully out positions, robot operation is impossible.

Hold-to-run button

The hold-to-run button allows movement when actuated manually and immediately stops any movement when released. The hold-to-run button can only be used in manual mode.

How to operate the hold-to-run buttons is detailed in section

How to use the hold-to-run function on page 196

.

3HAC 16590-1 Revision: B 25

1 Safety

1.4.1. Stop the system

1.4 How to deal with an emergency

1.4.1. Stop the system

Overview

Stop the system immediately if:

• there are any personnel in the robot working area, while the robot is working

• the robot causes harm to personnel or mechanical equipment

The FlexPendant emergency stop button

xx0300000449

A Emergency stop button

The controller emergency stop button

xx0300000450

A Emergency stop button

Other emergency stop devices

The plant designer may have placed additional emergency stop devices in convenient places.

Please consult your plant or cell documentation to find out where these are placed.

26 3HAC 16590-1 Revision: B

1 Safety

1.4.2. Release the robot holding brakes

1.4.2. Release the robot holding brakes

Overview

Battery power

Brake release buttons

Brake release buttons are placed differently depending on robot type, this is detailed in the

Product Manual.

Always learn where the buttons are placed on robot models you work with.

Precautions

In case of a plant or cell power outage the brake system may be powered by a battery. How to connect the battery is different for each robot model. This is detailed in the Product Manual delivered with the robot.

Before releasing the brakes verify:

• which way will the arm go?

• how will an entangled object be affected?

A minor damage can easily become serious if the consequences are not considered.

DANGER!

Releasing the brakes is a hazardous action that may cause injury and damage property. It must be done with great care and only when absolutely necessary.

Releasing brakes

The robot’s brakes may be manually released as long as power is available. As long as the controller's power switch is in its on position, power is available and applied even if the system is in emergency state.

Step Action

1.

If necessary, use an overhead crane, fork lift or similar to secure the robots arms.

2.

Make sure the robot is powered.

3.

Once more, make sure that damage to entangled objects is not extended when brakes are released.

4.

Press the appropriate brake release button to release the brake.

3HAC 16590-1 Revision: B 27

1 Safety

1.4.3. Extinguishing fires

1.4.3. Extinguishing fires

Precautions

In case of a fire always make sure both you and your coworkers are safe before performing any fire extinguishing activities. In case of injury always make sure these are treated first.

Select fire extinguisher

Always use carbon dioxide extinguishers when extinguishing fires in electrical equipment such as the robot or the controller. Do not use water or foam.

28 3HAC 16590-1 Revision: B

1 Safety

1.4.4. Recover from emergency stops

1.4.4. Recover from emergency stops

Overview

Recovering from an emergency stop is a simple but important procedure. This procedure ensures that the robot system is not returned to production while maintaining a hazardous condition.

Reset the latch of emergency stop buttons

All push-button style emergency stop devices have a latching feature that must be released in order to remove the emergency stop condition of the device.

In many cases this is done by twisting the push-button as marked, but there are also devices where you pull the button to release the latch.

Reset automatic emergency stop devices

All automatic emergency stop devices also have some kind of latching feature that must be released. Please consult your plant or cell documentation to see how your robot system is configured.

Recover from emergency stops

Step Action

1.

Make sure the hazardous situation that resulted in the emergency stop condition no longer exists.

2.

Locate and reset the device or devices that gave the emergency stop condition.

3.

Acknowledge the emergency stop event (20202) in the event log.

4.

Press the Motors On button to recover from the emergency stop condition.

The Motors On button

The Motors On button is located on the controller: en0400000920

A Motors on button

3HAC 16590-1 Revision: B 29

1 Safety

1.4.5. Return to the programmed path

1.4.5. Return to the programmed path

Overview

Stopping the robot’s movement by removing power to its motors often results in the robot slipping from its programmed path. This may occur after an uncontrolled emergency or safety stop. The allowed slip distance is configured with system parameters. The distance can be different depending on operating mode.

If the robot is not within the configured allowed distance, you may chose to let the robot return to the programmed path or continue to the next programmed point in the path. Then the program execution continues automatically in programmed speed.

30 3HAC 16590-1 Revision: B

1 Safety

1.5.1. Overview

1.5 Working in a safe manner

1.5.1. Overview

About the robot

A robot is heavy and extremely powerful regardless of its speed. A pause or longer stop in movement can be followed by a fast hazardous movement. Even if a pattern of movement is predicted, a change in operation can be triggered by an external signal resulting in an unexpected movement without warning.

Therefore, it is important that all safety regulations are followed when entering safeguarded space.

About this section

In this section some most basic rules of conduct for you as a robot system user are suggested.

However, it is impossible to cover each and every specific situation.

3HAC 16590-1 Revision: B 31

1 Safety

1.5.2. For your own safety

1.5.2. For your own safety

General principles

A few simple principles should be followed in order to operate the robot system safely:

•

Always operate the robot system in manual mode if personnel are inside safeguarded space.

• Always bring the FlexPendant along when you enter safeguarded space so that robot control is in your hands.

•

Watch out for rotating or moving tools such as milling cutters and saws. Make sure those are stopped before you approach the robot.

• Watch out for hot surfaces both on work pieces as well as on the robot system. The robot’s motors can become fairly hot if run for a long time.

•

Watch out for grippers and objects gripped. If the gripper is opened the work piece could fall and cause injuries or damage equipment. The gripper can be very powerful and can also cause injuries if not operated in a safe manner.

• Watch out for hydraulic and pneumatic systems and live electric parts. Even with power off residual energy in such circuits can be very dangerous.

Disconnected FlexPendant

Always put away a disconnected FlexPendant safe from any robot cell or controller to avoid that a disconnected unit is used when trying to stop the robot in a hazardous situation.

CAUTION!

A disconnected FlexPendant should be stored in such a way that it cannot be mistaken for being connected to the controller.

Custom FlexPendant connections

Any means of connecting the FlexPendant except by the supplied cable and its standard connector must not render the emergency stop button inoperative.

Always test the emergency stop button to make sure it works if a custom connection cable is used.

Controller’s access panels

Access panels should only be opened by trained service personnel. There are no parts inside of use to others.

DANGER!

Danger of electrical shock or burn. High voltages inside controller cabinet. The robot and other equipment in the cell are also supplied with high voltages.

32 3HAC 16590-1 Revision: B

1 Safety

1.5.3. Handling of FlexPendant

1.5.3. Handling of FlexPendant

General instructions

The FlexPendant is a high-quality handheld terminal equipped with highly sensitive state-ofthe-art electronics. To avoid malfunctions or damage through improper handling, follow these instructions during operation.

The FlexPendant may only be used for the purposes mentioned in this manual. The

FlexPendant was developed, manufactured, tested and documented in accordance with applicable safety standards. If you follow the instructions regarding safety and use as described in this manual, the product will, in the normal case, neither cause personal injury nor damage to machinery and equipment.

CAUTION!

•

Turn off the power supply before opening the cable entrance area of the FlexPendant.

Otherwise the components could be destroyed or undefined signals could occur.

• Make sure that nobody trips over the cable to prevent the device from falling to the ground.

•

Take care not to squeeze and thus damage the cable with any object.

• Do not lay the cable over sharp edges since this can damage the cable sheath.

•

When not using the device, hang it on the wall bracket provided for storage.

• Never use sharp objects (e.g. screwdriver) for operating the touch screen. This could damage the touch screen.

CAUTION!

A disconnected FlexPendant should be stored in such a way that it cannot be mistaken for being connected to the controller.

Waste disposal

Observe the national regulations when disposing of electronic components! When replacing components equipped with batteries, please dispose of used batteries properly!

Foreseeable misuse of enabling device

Foreseeable misuse means that it is not allowed to fixate the enabling device in the enabling position. The foreseeable misuse of the enabling device must be restricted.

When releasing and then pressing the enabling device again, make sure to wait for the system to go to Motors Off state before pressing again. Otherwise you will receive an error message.

3HAC 16590-1 Revision: B 33

1 Safety

1.5.4. Safety tools

1.5.4. Safety tools

Safeguarding mechanisms

Your robot system can be equipped with a vast range of safeguards such as door interlocks, safety light curtains, safety mats, and others. The most common is the door interlock of the robot cell that temporarily stops the robot if you open it.

The controller has three separate safeguarding mechanisms, the general mode safeguarded

stop (GS), the automatic mode safeguarded stop (AS) and the superior safeguarded stop (SS).

Safeguards connected to...

are...

the GS mechanism the AS mechanism the SS mechanism always active regardless of the operating mode. only active when the system is in automatic mode. always active regardless of the operating mode.

Please consult your plant or cell documentation to see how your robot system is configured and where the safeguarding mechanisms are placed and how they work.

Safety supervision

The emergency stop and safeguarding mechanisms are supervised so that any failure is detected by the controller and the robot is stopped until the problem is solved.

Built-in safety safety stop functions

The controller continuously monitor hardware and software functionality. If any problems or errors are detected the robot is stopped until the problem has been solved.

If the failure is...

simple and can easily be solved minor and can be solved major, for instance concerns broken hardware

then...

a simple program stop is issued (SYSSTOP).

a SYSHALT is issued which results in a safety stop.

a SYSFAIL is issued which results in an emergency stop. The controller must be restarted in order to return to normal operation.

Restricting the robot’s working range

The robot’s working range can be restricted by means of mechanical stops or software functions, or by a combination of both.

Please consult your plant or cell documentation to see how your robot system is configured.

34 3HAC 16590-1 Revision: B

1 Safety

1.5.5. Safety in manual reduced speed and manual full speed mode

1.5.5. Safety in manual reduced speed and manual full speed mode

What is the manual mode?

The manual mode is most often used when creating programs and when commissioning a robot system.

There are two manual modes:

• manual reduced speed mode, usually called manual mode

• manual full speed mode (not available in all markets)

In manual mode, you need to press the enabling device to activate the robot’s motors.

What is the manual full speed mode?

In manual full speed mode the robot system can run in full speed. This mode is used when testing programs.

Operating speed

In manual reduced speed mode the robot can only be operated (moved) in reduced speed, 250 mm/s or slower. You should always operate in manual speed whenever working inside safeguarded space.

In manual full speed mode the robot moves in programmed speed. The manual full speed mode should only be used while all personnel are outside safeguarded space and only by specifically trained personnel extra aware of the implied risks.

Bypassed safeguard mechanisms

Automatic mode safeguarded stop (AS) mechanisms are all bypassed while operating in manual mode.

The enabling device

In manual mode the robot’s motors are activated by the enabling device on the FlexPendant.

This way the robot can only move as long as the device is pressed.

The enabling device is designed so that you must press its push-button just half-way to activate the robot’s motors. Both in its all-out and full-in positions the robot will not move.

The hold-to-run button

The hold-to-run button allows stepping or running a program in manual mode.

Note that jogging does not require the hold-to-run button, regardless of operating mode.

3HAC 16590-1 Revision: B 35

1 Safety

1.5.6. Safety in automatic mode

1.5.6. Safety in automatic mode

What is the automatic mode?

In automatic mode the enabling device is disconnected so that the robot can move without human intervention.

Active safeguard mechanisms

Both the general mode safeguarded stop (GS) mechanisms, the automatic mode safeguarded stop (AS) mechanisms and the superior safeguarded stop (SS) are all active while operating in automatic mode.

Coping with process disturbances

Process disturbances may not only affect a specific robot cell but an entire chain of systems even if the problem originates in a specific cell.

Extra care must be taken during such a disturbance since that chain of events may create hazardous operations not seen when operating the single robot cell. All remedial actions must be performed by personnel with good knowledge of the entire production line, not only the malfunctioning robot.

Process disturbance examples

A robot picking components from a conveyer might be taken out of production due to a mechanical malfunction, while the conveyer must remain running in order to continue production in the rest of the production line. This means, of course, that extra care must be taken by the personel preparing the robot in close proximity to the running conveyor.

A welding robot needs maintenance. Taking the welding robot out of production also means that a work bench as well as a material handling robot must be taken out of production to avoid personnel hazards.

36 3HAC 16590-1 Revision: B

2 Welcome to FlexPendant

2.1. About the Welcome to FlexPendant chapter

2 Welcome to FlexPendant

2.1. About the Welcome to FlexPendant chapter

Overview

The Welcome to FlexPendant chapter contain an overview on the FlexPendant, the IRC5 controller, and RobotStudio Online.

A basic IRC5 robot system normally consists of a controller, the FlexPendant, RobotStudio

Online and one or more robots or other mechanical units. There can also be one or more hardware or software options or additions. This manual describes a basic IRC5 system without options.

3HAC 16590-1 Revision: B 37

2 Welcome to FlexPendant

2.2. What is a FlexPendant?

2.2. What is a FlexPendant?

Description of FlexPendant

The FlexPendant (occasionally called TPU, or teach pendant unit) is a device for handling many of the functions involved with operating the robot system; running programs, jogging the manipulator, producing and editing application programs, etc.

The FlexPendant consists of both hardware, such as buttons and joystick, and software. The

FlexPendant is connected to the controller module through an integrated cable and connector.

NOTE that specific functions may not be performed using the FlexPendant, but only through

RobotStudio

Online

. How to perform these are specified in

Operator’s manual - RobotStudio

Online

.

Main parts

These are the main parts on the FlexPendant.

38 en0300000586

C

D

A

B

E

F

Connector

Touch screen

Emergency stop button

Enabling device

Joystick

Hold-to-run buttons (not included in all systems)

Continues on next page

3HAC 16590-1 Revision: B

2 Welcome to FlexPendant

2.2. What is a FlexPendant?

Continued

Hardware buttons

There are a number of dedicated hardware buttons on the FlexPendant. Four of them are programmable and four are pre-programmed.

en0300000587

A

B

C

D

E

F

G

H

Programmable key 1. How to define its function is detailed in section

Editing programmable keys on page 291

.

Programmable key 2. How to define its function is detailed in section

Editing programmable keys on page 291

.

Programmable key 3. How to define its function is detailed in section

Editing programmable keys on page 291

.

Programmable key 4. How to define its function is detailed in section

Editing programmable keys on page 291

.

START button. Starts program execution. In systems without hold-to-run buttons, the

Start button is also used for the hold-to-run function.

Step BACKWARD button. Steps the program one instruction backwards. In systems

without hold-to-run buttons, the Backward button is also used for the hold-to-run function.

Step FORWARD button. Steps the program one instruction forwards. In systems

without hold-to-run buttons, the Forward button is also used for the hold-to-run function.

STOP button. Stops the program execution.

3HAC 16590-1 Revision: B

Continues on next page

39

2 Welcome to FlexPendant

2.2. What is a FlexPendant?

Continued

Touch screen elements

The illustration shows the touch screen elements of the FlexPendant touch screen.

en0300000588

C

D

A

B

E

F

ABB menu

Operator window

Status bar

Close button

Task bar

Quickset menu

ABB menu

Operator window

The ABB menu contains programs, configurations, and applications. This is described in section

The ABB menu on page 73

.

The Operator window displays messages from the program. This is described in section

Operator window on page 94

.

Status bar

The Status bar displays information about the system and messages. This is described in section

Status bar on page 95

.

Close button

40

Tapping the close button closes the presently open view or application.

Continues on next page

3HAC 16590-1 Revision: B

2 Welcome to FlexPendant

2.2. What is a FlexPendant?

Continued

Task bar

The Task bar displays all open views and applications.

Quickset menu

The Quickset menu contains shortcuts to jogging and settings. This is described in section

The Quickset menu on page 96

.

Left and right handheld

The FlexPendant is set to left handheld on delivery. This can easily be changed to right handheld and back again whenever required.

en0400000913

3HAC 16590-1 Revision: B 41

2 Welcome to FlexPendant

2.3. What is an IRC5 controller?

2.3. What is an IRC5 controller?

The IRC5 controller

The IRC5 controller contains all functions needed to move and control the robot.

The base variant of the IRC5 controller, M2004, can consist of a single cabinet or be divided into two separate modules; the control module and the drive module. In a single cabinet, the control and drive module are integreted into one single module.

The control module contains all the control electronics such as main computer, I/O boards, and flash memory. The control module runs all software necessary for operating the robot

(that is the RobotWare system).

The drive module contains all the power electronics supplying the robot motors. An IRC5 drive module may contain nine drive units and handle six internal axes plus two or additional axes depending on the robot model.

When running more than one robot with one controller (MultiMove option), an extra drive module must be added for each additional robot. However, a single control module is used.

Read more about MultiMove in

Application manual - MultiMove

.

xx0400000730

A

B

Control module

Drive module

42 3HAC 16590-1 Revision: B

2 Welcome to FlexPendant

2.4. What is RobotStudio Online?

2.4. What is RobotStudio Online?

Preparations

RobotStudio Online runs on a PC that must be connected either to a controller network or to the controller’s service port.

If you are about to install over the controller network you need to know the name or IP address of the controller. You also need to know where the system to be installed is stored, on the PC’s hard disk, on a supplied CD or elsewhere.

References

All procedures are detailed in the RobotStudio Online operator's manual.

How to choose what activities to perform using either RobotStudio Online or the FlexPendant is specified in section

When to use the FlexPendant and RobotStudio Online on page 44

.

3HAC 16590-1 Revision: B 43

2 Welcome to FlexPendant

2.5. When to use the FlexPendant and RobotStudio Online

2.5. When to use the FlexPendant and RobotStudio Online

Overview

For operating and managing the robot, you either use the FlexPendant or RobotStudio

Online

.

The FlexPendant is optimized for handling robot motions and ordinary operation, and

RobotStudio

Online

is optimized for configuration, programming and other tasks not related to the daily operation.

Start, restart and shut down the controller

To...

Start the controller.

Restart the controller.

Shut down the controller.

Use...

The power switch on the controller’s front panel .

The FlexPendant, RobotStudio Online or the power switch on the controller’s front panel .

The power switch on the controller’s front panel.

Run and control robot programs

To...

Use...

Jog a robot.

The FlexPendant

Start or stop a robot program. The FlexPendant

Communicate with the controller

To...

Acknowledge events.

View and save the controller’s event logs.

Back up the controller’s software to files on the PC or a server.

Back up the controller’s software to files on the controller

Transfer files between the controller and network drives.

Use...

The FlexPendant.

RobotStudio Online or the FlexPendant.

RobotStudio Online or the FlexPendant.

The FlexPendant.

RobotStudio Online or the FlexPendant.

44

Continues on next page

3HAC 16590-1 Revision: B

2 Welcome to FlexPendant

2.5. When to use the FlexPendant and RobotStudio Online

Continued

Program a robot

To...

Use...

Create or edit robot programs in a flexible way. This is suitable for complex programs with a lot of logic, I/O signals or action instructions.

RobotStudio Online to create the program’s structure and most of the source code and the FlexPendant to store robot positions and make final adjustments to the program.

When programming, RobotStudio

Online

provides the following advantages:

• A text editor optimized for RAPID code, with auto-text and tool-tip information about instructions and parameters.

• Program check with program error marking.

• Close access to configuration and I/O editing.

Create or edit a robot program in a supportive way. This is suitable for programs that mostly consist of move instructions.

The FlexPendant.

When programming, the FlexPendant provides the following advantages:

• Instruction pick lists

• Program check and debug while writing

• Possibility to create robot positions while programming

Add or edit robot positions.

The FlexPendant.

Modify robot positions.

The FlexPendant.

Configure the robot’s system parameters

To...

Edit the system parameters of the running system.

Save the robot's system parameters as configuration files.

Load system parameters from configuration files to the running system.

Load calibration data.

Use...

RobotStudio Online or the FlexPendant

RobotStudio Online or the FlexPendant

RobotStudio Online or the FlexPendant

RobotStudio Online or the FlexPendant

Create, modify and install systems

To...

Create or modify a system.

Use...

RobotStudio Online together with RobotWare and a valid RobotWare Key.

RobotStudio Online

Install a system on a controller.

Install a system on a controller from a USB memory.

The FlexPendant.

3HAC 16590-1 Revision: B

Continues on next page

45

2 Welcome to FlexPendant

2.5. When to use the FlexPendant and RobotStudio Online

Continued

Calibration

To...

Calibrate base frame etc.

Calibrate tools, work objects etc.

Use...

The FlexPendant

The FlexPendant

Related information

The table below specifies which manuals to read, when performing the various tasks referred to:

Recommended use...

for details, see manual...

FlexPendant

RobotStudio Online

Operator’s manual - IRC5 with

FlexPendant

Operator’s manual -

RobotStudio Online

Document number

3HAC 16590-1

3HAC 18236-1

46 3HAC 16590-1 Revision: B

2.6. Buttons on the controller

Buttons on the control module

2 Welcome to FlexPendant

2.6. Buttons on the controller en0400000784

Functions for buttons on the control module

This section describes the control module button functions or where to find such information.

B

C

D

Part

A

Description

Main Power ON/OFF

Function

ON/OFF Switch for system shut down.

Described in section:

•

Start up in automatic mode on page 229

•

Start up in manual mode on page 231

Emergency stop button

Motors On

Mode switch

The different statuses of the motors on lamp is described in the Trouble shooting manual - IRC5.

Described in section:

•

Present operating mode on page 225

•

About the manual mode on page 228

•

About the automatic mode on page 227

3HAC 16590-1 Revision: B

Continues on next page

47

2 Welcome to FlexPendant

2.6. Buttons on the controller

Continued

Ports on the control module

On the front of the control module are also a service port, and optionally a USB port. Both are located below the buttons and may be hidden by a small protective hatch.

The service port is described in section

Connecting a PC to the service port on page 52

.

The USB port can be used wih a USB memory device to load or save programs, data, or other information to and from the controller. See section

USB memory information on page 252

.

xx0400001299

A Service port on control module front

Buttons on the drive module

en0400000797

Functions for buttons on the drive module

This section describes the buttons and their functions on the drive module.

Description

Switch ON/OFF

Function

ON/OFF switch for the drive module alone.

48 3HAC 16590-1 Revision: B

3 Get started

3.1. About the Get started chapter

3 Get started

3.1. About the Get started chapter

Overview

The Get started chapter describes how to connect the FlexPendant to the FlexController, and the network connections. It also describes a number of action scenarios, an overview of ofter performed work tasks with the FlexPendant.

3HAC 16590-1 Revision: B 49

3 Get started

3.2.1. Connecting a FlexPendant

3.2 Connections

3.2.1. Connecting a FlexPendant

Location of FlexPendant connector

The FlexPendant connector is located as shown below.

xx0400000729

A FlexPendant socket connector

Connecting a FlexPendant

Step

1.

Action

Locate the FlexPendant socket connector on the controller.

Illustration

2.

3.

Plug in the FlexPendant cable connector.

Screw the connector lock ring firmly by turning it clockwise. xx0400000931

• O: FlexPendant connector

(A22.X1)

50 3HAC 16590-1 Revision: B

3 Get started

3.2.2. Disconnecting a FlexPendant

3.2.2. Disconnecting a FlexPendant

Disconnecting a FlexPendant

This procedure details how to disconnect a FlexPendant

Step

1.

2.

3.

4.

Action

Finish any ongoing activities that require the FlexPendant to be connected. (For instance path adjustments, calibration, program changes.)

Shut down the system. If the system is not shut down when disconnecting the

FlexPendant it will go to the emergency stop state.

Unscrew the connector cable counter clockwise.

Store the FlexPendant safely away from any robot system.

3HAC 16590-1 Revision: B 51

3 Get started

3.2.3. Connecting a PC to the service port

3.2.3. Connecting a PC to the service port

NOTE!

The service port shall only be used for direct connection to a PC as described in this procedure. It must not be connected to a LAN (local area network), since it has a DHCP server that automatically distributes IP addresses to all units connected to the LAN. Contact your network administrator if you need more information.

CAUTION!

When a cable is connected to the service port on the Control Module front and the service hatch is opened, the controller will not comply with the requirements of protection class IP54.

Ports

The illustration below shows the two main ports on the computer unit: the Service Port and the LAN port. Make sure the LAN (factory network) is not connected to any of the service ports!

52 xx0400001299

A

B

C

Service port on the Control Module front

Service port on computer unit (connected to Service port on the Control Module front through a cable)

LAN port on computer unit (connects to factory LAN)

Connections to ports may be done as detailed below:

Connection to/from:

Connecting the Control Module to the factory LAN

Connecting a PC to the Control Module service port.

Detailed in section:

Proceed as detailed in section Installation in the Product Manual, IRC5.

Proceed as detailed below!

Continues on next page

3HAC 16590-1 Revision: B

3 Get started

3.2.3. Connecting a PC to the service port

Continued

Connecting a pc to the service port

Step

1.

2.

3.

Action

Make sure the network setting on the

PC to be connected is correct.

Use the delivered category 5 Ethernet crossover boot cable with RJ45 connectors.

Connect the network cable to the network port of your PC

Illustration

Refer to the system documentation for your PC, depending on the operative system you are running.

The PC must be set to “Obtain an IP address automatically”.

The cable is delivered in the RobotWare product box.

4.

Connect the boot cable to the service port, placed on the control module front. xx0400000844

• A: network port

The placement of the network port may vary depending on the pc model.

3HAC 16590-1 Revision: B 53

3 Get started

3.2.4. Set up the network connection

3.2.4. Set up the network connection

When do I need to setup the network connection?

You need to setup the controller’s network connection when the controller is connected to a network for the first time or when the network addressing scheme changes.

Preparations

If an IP address is to be obtained automatically, make sure there is a server running that supplies the network with IP addresses (a DHCP server). Otherwise you will not be able to access the controller via the controller network.

It is still possible to access the controller via the service PC connection.

Network connection dialog box

The illustration shows the network connection dialog box. en0400000902

Set up the network connection

Regardless of how you choose to set up the network connections, the first steps are common:

54

Step

1.

2.

3.

4.

Action Info

You may reach the boot application by performing an X-start.

How to perform an X-start is detailed in

section

Restart and select another system (X-start) on page 258

.

In the boot application, tap Settings.

The network connection dialog is displayed.

If you choose to use no IP address, the tap Use no IP address . Otherwise, proceed below!

In some cases it can be useful to disconnect the controller from the network, without disconnecting the network cable. Without IP address the controller cannot be accessed from other equipment on the same network.

If you choose to obtain an IP address automatically, the tap Obtain an IP

address automatically. Otherwise, proceed below!

Continues on next page

3HAC 16590-1 Revision: B

3 Get started

3.2.4. Set up the network connection

Continued

Step

5.

6.

7.

Action

If you choose to use a fixed IP address, tap Use the following IP address.

Enter a valid IP address, a valid subnet mask, and the IP address of the default gateway to use.

Tap OK to save the new setting.

In the boot application, tap Restart

Controller to restart the controller and use the new setting.

Info

3HAC 16590-1 Revision: B 55

3 Get started

3.3.1. About the Action Scenarios chapter

3.3 Action scenarios

3.3.1. About the Action Scenarios chapter

Overview

This chapter contains brief procedures detailing a number of typical actions a typical user may perform. It also contains many references to detailed information about the same subjects.

The brief information given, is intended to be used directly by experienced users, while the references may be more adequate for novices and for training purposes.

More information

Note that there may be more information available than the one referred to in the procedures.

Information about:

• a specific menu is described in chapter

Navigating and handling FlexPendant on page

71

.

• a specific button on the FlexPendant is described in

What is a FlexPendant? on page

38

.

• a specific button is described in chapter

What is an IRC5 controller? on page 42

for tasks performed using the controls on the controller modules.

•

how to perform a specific task is detailed in the tasks chapters, e.g.

Programming and testing on page 133

or

Running in production on page 219

.

56 3HAC 16590-1 Revision: B

3 Get started

3.3.2. System start up

3.3.2. System start up

Prerequisites before start up

This procedure details the main steps required to start the system when the power has been switched off.

All information is based on the assumption that working system software has already been

installed on the robot controller, as the case would be at first start-up directly after delivery.

No information is given in this manual about how to connect the controller to a LAN (Local

Area Network), but this is detailed in the Installation section of the

Product Manual - IRC5

.

Note that there may be more information available than the one referred to in the procedure.

System start up

This procedure details all required steps to start the system for the first time. For everyday startup, step 4 is normally the only required step.

Step

1.

2.

3.

4.

5.

6.

3HAC 16590-1 Revision: B

Action

Install the robot equipment.

Info

Mechanical installation and electrical connections between manipulator and controller cabinet is described in the

Product Manual

of the robot and controller respectively.

How to connect the safety circuits is detailed in the robot’s

Product Manual

.

Make sure the safety circuits of the system are properly connected to the robot cell or have jumper connections installed (if required).

Connect the FlexPendant to the controller cabinet.

Switch the power on.

If the controller or manipulator have been replaced with spare parts, make sure the calibration values, revolution counters and serial numbers are updated correctly.

This step is only required if the robot system will be connected to a network.

Perform an X-start.

The Boot Application is started.

The FlexPendant and its major parts and functions are detailed in section

What is a FlexPendant? on page 38

How to connect the FlexPendant to the cabinet is detailed in section

Connecting a FlexPendant on page 50

Use the main switch on the control module.

Normally, only the revolution counters require updating, which is to be performed as detailed in section

Updating revolution counters on page

274

.

If required, transfer the calibration data from the serial measurement board as detailed in

Serial Measurement Board memory on page 280

for systems

without the AbsAcc option.

If required, enter the calibration data as detailed in

Loading calibration data using the FlexPendant on page 276

for systems with the AbsAcc option.

Detailed in section

Restart and select another system (X-start) on page 258

.

Continues on next page

57

3 Get started

3.3.2. System start up

Continued

Step Action Info

7.

This step is only required if the robot system will be connected to a network.

Use the boot application to:

• set the IP address of the controller cabinet

• set the network connections

• select the system

• restart the system

The system is restarted.

Install RobotStudio

Online

on a PC.

How to use the boot application is detailed in section

Using the boot application on page 254

.

At this point, a single system is available.

8.

9.

Connect the controller to a PC (through the service port) or to the network (if used).

Connect a PC to the Control

Moduleservice port.

10.

Start RobotStudio

Online

on the PC.

Proceed as detailed in section

Connecting a PC to the service port on page 52

.

Also see section

Set up the network connection on page 54

.

Proceed as detailed in section

Accessing a controller from

RobotStudio Online

in the

Operator’s manual - RobotStudio Online

.

11.

Restart the controller.

12.

The robot system is now ready for operation.

Proceed as detailed in section

Installing

RobotStudio Online

in the

Operator’s manual - RobotStudio Online

.

RobotStudio

Online

is used to create a system to run on the controller, but at this point (prior to the first start-up) a system is already installed by the manufacturer.

58 3HAC 16590-1 Revision: B

3 Get started

3.3.3. Jogging

3.3.3. Jogging

Jogging

This procedure details the main steps required to jog the robot.

The term Jogging is described in section

Introduction to jogging on page 105

.

Note that there may be more information available than the one referred to in the procedure.

Step

1.

2.

3.

4.

5.

Action Info

It is possible to jog the robot under the following conditions:

• The system has been started as detailed in this manual.

• no programmed operation is running

• the system is in Manual mode.

• the enabling device is pressed and the system is in Motors On state

The Manual mode is described in section

About the manual mode on page 228

.

Starting in the Manual mode is detailed in section

Start up in manual mode on page 231

.

How to switch to manual mode is detailed in section

Switching from automatic to manual mode on page

235

.

Many of the mechanical units connected to the controller may be jogged.

How to determine which mechanical unit to jog is detailed in section

Selecting mechanical unit on page 108

.

The robot may be jogged in several ways, in different coordinate systems.

First, determine in which way you want to jog.

The difference between different types of jogging is detailed in section

Introduction to jogging on page 105

.

How to jog the robot axis by axis is detailed in section

Jog axis by axis on page 114

.

The robot may be jogged in:

•

Jog in base coordinates on page

116

•

Jog in tool coordinates on page

120

•

Jog in world coordinates on page

117

•

Jog in work object coordinates on page 119

Once a mechanical unit has been selected, its axes may be jogged in different ways.

These ways may be selected using the

QuickSet menu.

Define the working range for the robot/ robots as well as for any other pieces of equipment working in the robot cell.

The robot’s working range is defined by system parameters. See section

Configuring system parameters on page 270

or Technical reference

manual - System parameters.

3HAC 16590-1 Revision: B

Continues on next page

59

3 Get started

3.3.3. Jogging

Continued

Step

6.

7.

Action

Jog the manipulator using the joystick on the FlexPendant.

In some cases, more than one manipulator may be jogged simultaneously. This requires the

MultiMove option to be installed.

Info

The FlexPendant and its various parts and sections are described in section

What is a FlexPendant? on page 38

.

The joystick and how to map the directions of it, is detailed in section

Selecting motion mode on page 110

.

How to prevent causing manipulator movements in certain directions while jogging, is detailed in section

Locking the joystick in specific directions on page 122

.

There might be restrictions to how you

can jog, see section

Restrictions to jogging on page 106

.

How to jog multiple manipulators is detailed in section

Coordinated jogging on page 107

.

60 3HAC 16590-1 Revision: B

3 Get started

3.3.4. Using RAPID programs

3.3.4. Using RAPID programs

Using the RAPID program

This procedure describes the main steps required in creating, saving, editing and debugging any RAPID program.

Note that there is more information available, than the one referred to in the procedure. The concept RAPID program is described in section

The structure of a RAPID application on page 134

.

Step

1.

2.

3.

4.

5.

6.

7.

8.

Action Info

Start by creating a RAPID program.

Edit your program.

How to create a RAPID program is detailed in section

Handling of programs on page 165

.

Proceed as detailed in section

Handling of instructions on page 176

.

To simplify programming and keep an overview of the program, you may want to divide the program into more than one module.

The module concept is described in section

The structure of a RAPID application on page 134

.

How to view, add, or delete a module is

detailed in section

Handling of modules on page 168

.

To further simplify programming, you may want to divide the module into more than one routine.

The routine concept is described in section

The structure of a RAPID application on page 134

.

How to add or delete a routine is detailed in section

Handling of routines on page 172

.

When programming you may want to work with:

• Tools

• Work objects

• Payloads

Also read the following sections:

•

Creating a tool on page 142

.

•

Creating a work object on page

154

.

•

Creating a payload on page 161

.

Based on the four elements specified above, program execution may automatically be displaced to better suit e.g. the tools as they wear down, etc.

In order to deal with potential errors that may occur during program execution, you may want to create an error handler.

Error handlers are described in RAPID

overview.

After completing the actual RAPID program, it will require testing before being put into production.

Proceed as detailed in section

Testing on page 196

.

3HAC 16590-1 Revision: B

Continues on next page

61

3 Get started

3.3.4. Using RAPID programs

Continued

Step Action Info

9.

After test running your RAPID program, it may require altering. You may want to modify, or tune, programmed positions, the TCP positions, or paths.

How to modify positions while the program is running is described in

section

HotEdit on page 73

.

How to modify positions in manual

mode is described in section

Modifying positions on page 184

.

10.

Programs that are no longer required may be removed.

See

Deleting programs from memory on page 192

.

Also see

Deleting programs from hard disk on page 194

.

Running the program

This procedure specifies how to use an existing RAPID program.

Step

1.

2.

3.

4.

Action

Load an existing program.

When starting program execution, you may choose between running the program once, or running it continuously.

Once the program has been loaded, you may start program execution.

After program execution is completed, the program may be stopped.

Info

Described in section

Starting programs on page 219

.

Described in section

Quickset menu,

Run Mode on page 201

.

Described in section

Starting programs on page 219

and in

Using multitasking programs on page 222

.

Proceed as detailed in section

Stopping programs on page 221

.

62 3HAC 16590-1 Revision: B

3 Get started

3.3.5. Working with inputs and outputs

3.3.5. Working with inputs and outputs

Working with inputs and outputs

This procedure details the main steps required to set outputs, read inputs and configure I/O units.

Note that there may be more information available than the one referred to in the procedure.

Step

1.

2.

3.

4.

5.

6.

7.

8.

Action Info

You may want to create a new I/O.

Before using any input or output, the system must be configured to enable the I/O functions.

I/O signals are created using system parameters, see section

Configuring system parameters on page 270

.

Configuring the system is done when creating the system. How to do this is detailed in

Operator’s manual -

RobotStudio Online

.

You may set a value to a specific digital

output.

Proceed as detailed in section

Simulating and changing signal values on page 238

.

You may set a value to a specific analog

output.

Proceed as detailed in section

Simulating and changing signal values on page 238

.

You may view the status of a specific

digital input.

Proceed as detailed in section

Simulating and changing signal values on page 238

.

You may view the status of a specific

analog input.

Safety signals.

How to edit an I/O.

Proceed as detailed in section

Simulating and changing signal values on page 238

.

Signal explanation is detailed in

Safety

I/O signals on page 240

Proceed as detailed in section

Simulating and changing signal values on page 238

.

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3.3.6. Backup and restore

3.3.6. Backup and restore

Backup and restore

The contents of a typical backup is specified in section

What is saved on backup? on page

265

. How to perform the backup is detailed in section

Backup the system on page 267

.

Re-introducing the previously saved memory contents from the backup into the robot controller is called performing a restore. How to perform the restore is detailed in section

Restore the system on page 268

.

Information about starts is described in

Restart overview on page 253

.

Note that there may be more information available than the one referred to above.

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3 Get started

3.3.7. Running in production

3.3.7. Running in production

Running in production

This instruction details the main steps useful when running the system in automatic mode

(production mode).

Note that there may be more information available than the one referred to in the procedure.

Step Action Info

1.

2.

3.

Start the system as detailed in section

System start up on page 57

.

If the system is using UAS, User

Authorization System, the user must log into the system before starting operation.

How to log in is described in section

How to logout and login on page 103

.

Load a program.

How to load a program is described in

Handling of programs on page 165

.

4.

5.

Before starting system choose mode to start in on the FlexController.

How to choose mode is described in section

Switching from manual to automatic mode on page 234

.

Start by pressing the Start button on the

FlexPendant.

The FlexPendant’s hardware buttons are described in

What is a

FlexPendant? on page 38

.

6.

7.

The controller system communicates with the operator through messages displayed on the FlexPendant screen.

Messages can be either event messages or RAPID instructions, e.g.

TPWrite

.

Event messages describe an event occurring within the system, and is saved in an event log.

The basic concepts are described in section

Accessing the event log on page 243

.

RAPID instructions

TPReadFK

and

TPWrite

are described in RAPID

reference manual - Instructions.

In manual mode, the Modify Position function allows the operator to make adjustments to the robot positions in a

RAPID program.

The HotEdit function allows the operator to make adjustments to programmed positions in both automatic and manual mode.

How to modify position is described in

sections

Modifying positions on page

184

and in

HotEdit on page 73

8.

In a production process you may want to stop the robot.

How to stop production is described in

section

Stopping programs on page 221

9.

In the Production Window you can supervise the ongoing process.

The Production window is described in section

Production window on page 79

10.

When ending operation, the user should log out.

How to log in is described in section

How to logout and login on page 103

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3 Get started

3.3.8. Granting access for RobotStudio Online

3.3.8. Granting access for RobotStudio Online

About write access on the controller

The controller only accepts one user with write access at a time. Users in RobotStudio Online can request write access to the system and this request is accepted or rejected on the

FlexPendant. This can only be done in manual mode.

Granting access for RobotStudio Online

This procedure describes how to grant access for RobotStudio Online.

Step

1.

2.

Action

When a user in RobotStudio Online requests access, a message is displayed on the FlexPendant. Decide whether to grant or reject access.

If you want to grant access, then tap Grant. The user holds write access until he disconnects or until you reject the access.

If you want to deny access, then tap Reject.

If you have granted access and want to revoke the access, tap Reject.

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3 Get started

3.3.9. Upgrading

3.3.9. Upgrading

Upgrading

This procedure details the main steps required to correctly upgrade the system. By upgrading we mean changing hardware, such as replacing circuit board with newer versions, as well as loading software with later releases.

Note that there may be more information available than the one referred to in the procedure.

Type of upgrade Info

When replacing circuit boards such as buses,

I/O boards, etc., with newer versions, the system will automatically reflash the unit.

What happens during reflashing is detailed in

section

Reflashing firmware and

FlexPendant on page 263

.

xx0100000003

During reflashing, the system may restart several times, and it is vital not to shut down the system, or in any other way interrupt the automatic process.

When upgrading the robot or controller mechanically, fitting instructions are normally delivered with the kit.

If no such instruction are provided, useful information may be found in the Repair section of the Product Manual of the equipment in question.

When upgrading the system software, the system must be changed in order to reflect the additions.

A new license key may be required.

How to modify an existing system is detailed in section

How to Modify a System

in the

Operator’s manual - RobotStudio Online.

How to create a new system is detailed in section

Creating a new system

in the

Operator’s manual - RobotStudio Online.

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3 Get started

3.3.10. Installing software options

3.3.10. Installing software options

Installing software options

The main steps required to correctly install a generic software option or option package is described in Operator’s manual - RobotStudio Online.

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3 Get started

3.3.11. Shutting down

3.3.11. Shutting down

Shutting down

This procedure describes how to shut down the system and turn off power.

Step

1.

2.

3.

Action Info

Stop all running programs.

Shut down the system using the On/Off switch on the FlexController.

If you want to protect the FlexPendant you can unplug it and store it elsewhere when the system has shut down.

How to disconnect the FlexPendant from the controller is detailed in section

Disconnecting a FlexPendant on page

51

.

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3 Get started

3.3.12. General procedure when trouble shooting

3.3.12. General procedure when trouble shooting

Types of faults

Faults occurring in the robot system may be of two categories:

•

Faults detected by the built-in diagnostics system. These faults are described in section

Event log messages

in Trouble shooting manual - IRC5.

• Faults NOT detected by the built-in diagnostics system. These faults are described in section

Other types of faults

in Trouble shooting manual - IRC5.

Faults causing error message on the FlexPendant

The control system is supplied with diagnostic software to facilitate trouble shooting and to reduce downtime. Any errors detected by the diagnostics are displayed in plain language with a code number on the FlexPendant.

All system and error messages are logged in a common log in which the last 150 messages are saved. The log can be accessed from the Status bar on the FlexPendant.

To facilitate trouble shooting, it is important that some basic principles are followed. These are specified in

Trouble shooting principles

in Trouble shooting manual - IRC5.

Step

1.

2.

3.

4.

5.

Action Info

Read the error message displayed on the FlexPendant and follow any instructions given.

How to interpret the messages is detailed in section

Overview, event log messages

in Trouble shooting manual -

IRC5.

Was the information given on the

FlexPendant enough to solve the problem?

If yes; resume operation.

If no; proceed below.

If relevant, check the LEDs on the units. Each unit is thoroughly described in section

Unit LEDs

in Trouble shooting

manual - IRC5, including a description of its LEDs.

If relevant, check the cables, etc., with help of the circuit diagram.

Replace, adjust or fix as detailed in the

Repairs instruction if required.

All relevant document numbers are specified in section Document

references, IRC5 in Trouble shooting

manual - IRC5.

All relevant document numbers are specified in section

Document references, IRC5

in the Trouble

shooting manual - IRC5.

Faults NOT causing error messages on the FlexPendant

These faults are not detected by the diagnostic system and are handled in other ways. The way the symptom of the fault is observed greatly influences the type of fault. Instructions are given in section

Other types of faults

in Trouble shooting manual - IRC5.

To trouble shoot faults NOT causing error messages on the FlexPendant, follow steps 3 and

4 in the procedure in

Faults causing error message on the FlexPendant on page 70

.

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4 Navigating and handling FlexPendant

4.1. About the Navigate and handle FlexPendant chapter

4 Navigating and handling FlexPendant

4.1. About the Navigate and handle FlexPendant chapter

Overview

This chapter describes the touch screen elements on the FlexPendant, i.e. the menues.

Each menu is described in overview, with references to more information on how to use the functions. Note that this manual only covers menues in the basic RobotWare system, without options. All options are described in the application manuals.

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4 Navigating and handling FlexPendant

4.2. Overview, personalizing the FlexPendant

4.2. Overview, personalizing the FlexPendant

Personalizing

The FlexPendant can be personalized in a number of ways. How to do this is described in the following sections:

How to: is described in section:

change the language used in windows and dialogs

Changing language on page 290

.

change the display’s brightness and contrast

Changing brightness and contrast on page

285

.

rotate the FlexPendant for Left/Right handheld use configure views for program start and user authorization system recalibrate the touch screen

Switching between left and right handheld

FlexPendant on page 286

.

Configuring view settings on page 295

.

Calibrating the touch screen on page 298

.

configure programmable keys configure most common I/O list change background image change the date and time

Editing programmable keys on page 291

Changing date and time on page 288

.

.

Configuring Most Common I/O on page 289

Changing background image on page 297

.

.

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4 Navigating and handling FlexPendant

4.3.1. HotEdit

4.3 The ABB menu

4.3.1. HotEdit

HotEdit

HotEdit is a function for editing programmed positions. This can be done in all operating modes, even while the program is running.

When modifying a position, both the coordinates and the orientation can be changed. Note that the changed offset values are not stored in the original baseline of the program until a

Commit command has been applied. The changed values are however used directly in the loaded program.

HotEdit can only be used for positions of the type robtarget.

If a position is changed during operation, the current path may be affected. It is not recommended to modify positions close to the program pointer or the motion pointer since it is hard to predict when changes will take effect if they occur between the two pointers.

Therefore it is important to be certain of where in the program the robot is before changing any values while the program is running.

The functions available in HotEdit may be restricted by the user authorization system, UAS.

Illustration of HotEdit menu

en0500001542

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4 Navigating and handling FlexPendant

4.3.1. HotEdit

Continued

Functions available in HotEdit

Target selection

Selected targets

File

Baseline

Tune targets

APPLY

Lists all named positions in a tree view. Select positions and add them to the section by tapping the arrow. Note that if a position is used in more than one routine, it will appear in all places used and any changes made to the offset will be the same for everywhere it is used.

Lists all selected positions and their current offset. Tap the trash can to the right of the position name to remove them from the selection.

You can save and load selections of often used positions using the

File menu. If your system uses UAS, this may be the only way to select positions for editing.

The baseline menu is used to apply or reject changes to the original

(baseline) system, for both HotEdit and position modifications in the

Program editor.

For position modifications in the Program editor, the baseline menu is can only be used for systems with absolute limit modpos, where the allowed change distance is limited. See system parameters for the type ModPos Settings in Technical reference manual - System

parameters.

The original values are not changed until a Commit command has been applied.

To apply or reject the changes made to offset values, tap:

• Restore to original to discard all changes to the currently selected target positions

• Restore entire program to original to discard all changes to target positions (also applies to changes made in the program editor)

• Commit to current to apply all current changes to the selected target positions

• Commit entire program to current to apply all changes to target positions (also applies to changes made in the program editor)

Tap Tune targets to display a keyboard for editing the offset values

(coordinates and orientation).

The offset value is the length of the vector calculated from the original value and the changed value (x, y, and z, and orientation) in the Tune targets menu.

Tap APPLY to apply changes made in the Tune targets menu.

Note that this does not change the original values for the positions!

Related information

Positions can also be modified by jogging the robot to the new position, see section

Modifying positions on page 184

.

RAPID reference manual - Functions and datatypes.

Technical reference manual - System parameters, chapter Controller.

What is “the memory”? on page 248

.

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4 Navigating and handling FlexPendant

4.3.2. FlexPendant Explorer

4.3.2. FlexPendant Explorer

About FlexPendant Explorer

The FlexPendant Explorer is a file manager, similar to Windows Explorer, with which you can view the file system on the controller. You can also rename, delete, or move files or folders.

Illustration FlexPendant Explorer

The illustration details the FlexPendant Explorer.

en0400001130

Parts FlexPendant Explorer

The table below describes the parts in the illustration above.

Part Description

C

D

A

B

E

F

Simple view

Detailed view

Path

Menu

New folder

Up one level

Function

Tap to hide type in the file window

Tap to show type in the file window

Displays the directory path

Tap to display menu with functions for file handling

Tap to create new folder in present folder.

Tap to change to parent folder

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4.3.3. Inputs and outputs, I/O

4.3.3. Inputs and outputs, I/O

Inputs and outputs

Inputs and outputs, I/O, are signals used in the robot system. Signals are configured with system parameters, see section

Configuring system parameters on page 270

.

The Inputs and outputs menu

This illustration details the Inputs and outputs menu.

en04000000770

What is a signal

An I/O signal is the logical software representation of an I/O signal located on a fieldbus unit that is connected to a fieldbus within the controller.

By specifying a signal, a logical representation of the real I/O signal is created. The signal configuration defines the specific system parameters for the signal that will control the behavior of the signal.

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4.3.4. Jogging

4.3.4. Jogging

Overview

The Jogging functions are found in the Jogging window. The most commonly used are also available under the Quickset menu.

Jogging menu

The illustration shows the functions available under the Jogging menu: en0400000654

Property/button

Mechanical unit

Absolute accuracy

Motion mode

Coordinate system

Tool

Work object

Payload

Function

Select active mechanical unit, described in section

Selecting mechanical unit on page 108

.

Absolute Accuracy: Off is default. If the robot has the Absolute

accuracy option, then Absolute Accuracy: On is displayed.

Select motion mode, described in section

Selecting motion mode on page 110

.

Select coordinate system, e.g. described in section

Jog in base coordinates on page 116

.

Select tool, described in section

Selecting tool, work object, and payload on page 112

.

Select work object, described in section

Selecting tool, work object, and payload on page 112

.

Select payload, described in section

Selecting tool, work object, and payload on page 112

.

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4 Navigating and handling FlexPendant

4.3.4. Jogging

Continued

Property/button

Joystick lock

Increment

Position

Position format

Joystick directions

Align...

Go To...

Activate...

Function

Select locking joystick directions, described in section

Locking the joystick in specific directions on page 122

.

Select movement increments, described in section

Incremental movement for precise positioning on page 124

.

Displays each axis position in relation to the selected coordinate system.

Select position format, described in section

How to read the exact position on page 126

.

Displays current joystick directions, depending on setting in Motion mode. See section

Selecting motion mode on page 110

.

Align the current tool to a coordinate system. See section

Aligning tools on page 187

.

Move the robot to a selected position/target. See section

Moving the robot to a programmed position on page 186

.

Activate a mechanical unit. See section

Activating mechanical units on page 195

.

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4.3.5. Production window

4.3.5. Production window

Overview

The Production window is used to view the program code while the program is running.

Illustration of the Production window

This section illustrates the Production window.

en0400000955

Production window parts and functions

This section describes the parts and functions in the Production window.

Use...

to...

Load Program...

load a new program. Note that the loaded program will not be saved.

Move PP to Main move the program pointer to the routine main.

Debug modify position, go to program pointer or motion pointer, or to open the

Program editor. How to use the Program editor is described in section

Program editor, e.g.

Handling of instructions on page 176

, or

Handling of routines on page 172

.

Debug is only available in manual mode.

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4.3.6. Program data

4.3.6. Program data

Overview

The Program data view contains functions for viewing and working with data types and instances. You can open more than one window of the Program data, which can be useful when working with many instances or data types.

Illustration of Program data

This section illustrates the Program data view.

80 en0400000659

Change scope changes scope of data types in the list, see section

Viewing data in specific tasks, modules, or routines on page 136

.

Show data shows all instances of the selected data type.

View shows all or only used data types.

Continues on next page

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4 Navigating and handling FlexPendant

4.3.6. Program data

Continued

Illustration of a data type instances

This section illustrates a list of instances for a data type.

en0500001571

Filter

New filters the instances, see

Filtering data on page 101

.

creates a new instance of the selected data type, see

Creating new data instance on page 137

.

Refresh

Edit value refreshes the list of instances.

edits the selected instance’s values, see

Editing data instances on page

139

.

View data types returns to the Program data menu.

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4.3.7. Program editor

4.3.7. Program editor

Overview

The Program editor is where you create or modify programs. You can open more than one window of the Program editor, which can be useful when working with multitasking programs for instance. The Program editor button in the task bar displays the name of the task.

Illustration of Program editor

This section illustrates the Program editor view.

82 en0400001143

Tasks and programs

Modules

Menu for program operations, see

Handling of programs on page 165

Lists all modules, see

Handling of modules on page 168

.

Routines

Lists all routines, see

Handling of routines on page 172

.

Add instruction Opens instruction menu, see

Handling of instructions on page 176

.

.

Edit

Debug

Opens edit menu, see

Handling of instructions on page 176

.

Functions for moving the program pointer, service routines etc, see

Running a service routine on page 209

.

Modify position

See

Modifying positions on page 184

.

Hide declarations

See

Hiding declarations in program code on page 191

.

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4.3.8. Backup and restore

4.3.8. Backup and restore

About backups

The Backup and restore menu is used for performing backups and restoring the system. See section

Backup and restore systems on page 265

.

Illustration of backup and restore

This is the Backup and restore menu.

xx0300000440

Backup current system

Restore system

See

Backup the system on page 267

.

See

Restore the system on page 268

.

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4.3.9. Calibration

4.3.9. Calibration

About calibration

The Calibration menu is used to calibrate mechanical units in the robot system. Calibration can be performed using the options Pendulum Calibration or Levelmeter Calibration

(alternative method). See respective instruction manual.

Illustration of Calibration menu

This illustration shows the Calibration menu. All mechanical units are listed and their calibration status is displayed in the Status column.

en0400001146

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4.3.9. Calibration

Continued

Calibration menu options

This illustration shows the Calibration menu options after selecting mechanical unit.

en0400000771

Revolution

Counters

Calibration

Parameters

SMB Memory

Base Frame

See section

Updating revolution counters on page 274

.

See sections

Loading calibration data using the FlexPendant on page

276

,

Editing motor calibration offset on page 277

, and

Fine calibration procedure on FlexPendant on page 278

.

See section

Serial Measurement Board memory on page 280

.

See section

4 points XZ calibration on page 283

.

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4.3.10. Control panel

4.3.10. Control panel

Control panel

The Control panel contains functions for customizing the robot system and the FlexPendant.

86 en0400000914

Appearance

Configuration

Date and Time Settings for date and time for the robot controller. See

Changing date and time on page 288

.

I/O Settings for configuring the Most Common I/O list. See

Common I/O on page 289

.

Configuring Most

Language

Settings to customize the display’s brightness and contrast. See

Changing brightness and contrast on page 285

.

Configuration of the system parameters configuration. See

Configuring system parameters on page 270

.

ProgKeys

Settings for current language for the robot controller. See

Changing language on page 290

.

Settings for the four programmable keys on the FlexPendant. See

Editing programmable keys on page 291

.

Supervision

System

Touch Screen

Settings for motion supervision and execution settings. See

Editing supervision settings on page 293

.

Configuration of views for operating mode switch and UAS, User

Authorization System. See

Configuring view settings on page 295

.

Recalibration settings for the touch screen. See

Calibrating the touch screen on page 298

.

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4 Navigating and handling FlexPendant

4.3.11. Event log menu

4.3.11. Event log menu

Event log

The table is a brief summary of all actions that may be performed with the event log.

xx0300000447

Actions

The log may be opened.

A specific message may be viewed.

If the log contents do not fit into a single screen, it may be scrolled and/or zoomed.

The log may be deleted.

The log may be saved.

The log may be closed.

Descriptions

How to do this is detailed in section

Accessing the event log on page 243

.

How to do this is detailed in section

View messages

.

How to do this is detailed in section

Scrolling and zooming on the FlexPendant on page

100

.

How to do this is detailed in section

Deleting log entries on page 244

.

How to do this is detailed in section

Saving log entries on page 245

.

How to do this is detailed in section

Accessing the event log on page 243

.

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4.3.11. Event log menu

Continued

An event log message

Each event log entry consists of a message describing the event in detail, and it often contains advice on how to solve the problem.

en0300000454

C

D

A

B

E

F

G

H

Event number. All errors are listed by numbers.

Event title. Briefly states what has happened.

Event time marker. Specifies exactly when the event occurred.

Description. A brief description of the event. Intended to assist in understanding the causes and implications of the event.

Consequences. A brief description of any consequences inflicted on the system, transition to other operation mode, emergency stop, caused by the particular event. Intended to assist in understanding the causes and implications of the event.

Probable causes. A list of probable causes, listed in order of probability.

Recommended actions. A list of the recommended correcting actions, based on the “Probable causes” specified above. These may range from “Replace the xx...” to “Run test program xx...”, i.e. may be actions to isolate the problem as well as fixing it.

Acknowledge or OK button.

Related information about logs

Event log messages and more information about the event log are described in Trouble

shooting manual - IRC5.

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4.3.12. Lock the screen

4.3.12. Lock the screen

Overview

The FlexPendant screen may be locked to prevent accidental interference, when e.g. cleaning the screen. How to clean the screen and when to do it is detailed in the

Product Manual -

IRC5

.

Locking the screen

This section describes how to lock the FlexPendant’s touch screen.

Step

1.

Action

On the ABB menu, tap Lock Screen.

The following screen is presented:

3HAC 16590-1 Revision: B en0400000657

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4.3.12. Lock the screen

Continued

Step

2.

Action

Tap Lock.

The following screen is presented:

3.

en0400000658

Tapping the two buttons in the correct sequence as specified will unlock the screen.

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4.3.13. System info

4.3.13. System info

System info

System info displays all settings, properties and program versions, valid for the controller and the installed system.

Illustration of System info view

en0400000968

Controller properties

Network connections

Installed systems

System properties

Control module

Options

Drive module

Drive module x

Options

Additional options

Name of the controller.

Settings for the service port and LAN.

Information on the installed systems.

information about the loaded system.

Name and key for the control module.

All installed RobotWare options and languages.

Lists all drive modules.

Name and key for drive module x.

Options for drive module x, with type of robot etc.

Any additional installed options.

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4.3.14. Restart

4.3.14. Restart

Restart

A running system normally does not need to be restarted.

Tap the ABB menu and then Restart to restart the system.

en0500001557

Related information

Restart overview on page 253

.

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4.3.15. Logout

4.3.15. Logout

The Logout menu

This section details the Logout menu. More about using this menu is described in

How to logout and login on page 103

.

Logout is availble under the ABB menu.

en0400000947

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4.4.1. Operator window

4.4 The status bar menu

4.4.1. Operator window

Operator window

The operator window displays messages from the program. In a multitasking system, all task’s messages are displayed in the same operator window. If a message requires action then a separate window for that task will be displayed.

The operator window is opened by tapping the icon to the right of the ABB logo in the status bar. The illustration shows an example of an operator window:

94 en0400000975

Clear

Do not show logs

Clears all messages

Hides all messages

Messages are written by the program author in RAPID. It can sometimes be useful to hide all messages since this window otherwise will pop up and take focus for each message.

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4.4.2. Status bar

4.4.2. Status bar

Illustration of status bar

The Status bar displays information about the current status, such as operational mode, system, and active mechanical unit.

en0300000490

Part

D

E

F

A

B

C

Name

Operator window

Operating mode

System name (and controller name)

Controller state

Program state

Mechanical units. The selected unit (and any unit coordinated with the selected) is marked with a border. Active units are displayed in color, while deactivated units are grey.

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4.5.1. The Quickset menu

4.5 The QuickSet menu

4.5.1. The Quickset menu

General

The QuickSet menu provides a quicker way to change among other things jog properties rather than using the Jogging view.

Each item of the menu uses a symbol to display the currently selected property value or setting. Tap the Quickset button to display available property values.

Illustration of the Quickset menu

This section describes the buttons in the Quickset menu.

96 en0300000471

Mechanical unit, see section

Quickset menu, Mechanical unit on page 128

Increment, see section

Quickset menu, Increment on page 132

Run Mode, see section

Quickset menu, Run Mode on page 201

Step Mode, see section

Quickset menu, Step Mode on page 203

Speed, see section

Quickset menu, Speed on page 208

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4 Navigating and handling FlexPendant

4.6.1. Using the soft keyboard

4.6 Basic procedures

4.6.1. Using the soft keyboard

Using the soft keyboard

The soft keyboard is used frequently when operating the system, e.g. when entering file names or parameter values.

The soft keyboard works as an ordinary keyboard with which you can place the insertion point, type and correct typing errors. Tap letters, numbers and special characters to enter your text or values.

Illustration soft keyboard

This illustration shows the soft keyboard on the FlexPendant.

en0300000491

Using international characters

All western characters can be used, also in usernames and passwords. To access international characters, tap the Int’l button on the soft keyboard.

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Continues on next page

97

4 Navigating and handling FlexPendant

4.6.1. Using the soft keyboard

Continued

How to change the insertion point

Tap the arrow keys to change the insertion point, for instance when correcting typing errors.

If you need to move...

then tap...

backward xx0300000492 forward xx0300000493

How to delete

1. Tap the Backspace key (top right) to delete characters to the left of the insertion point.

xx0300000494

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4 Navigating and handling FlexPendant

4.6.2. Messages on the FlexPendant

4.6.2. Messages on the FlexPendant

Overview of messages

The FlexPendant displays messages from the system. These can be status messages, error messages, program messages, or requests for action from the user. Some require actions, and some are plain information.

Event log messages

The event log messages are messages from the RobotWare system about system status, events, or errors.

How to work with the event log messages is described in section

Handling the event log on page 243

. All messages are also described in the manual Trouble shooting - IRC5.

System messages

Some messages sent out by the system are not from the event log. They can come from other applications, such as RobotStudio

Online

.

To be able to change configurations and settings in the system from RobotStudio

Online

, the user must request write access. This generates a message on the FlexPendant where the operator can grant or deny access. The operator can at any time decide to withdraw the write access.

How to request access and work with RobotStudio

Online

is described in Operator’s manual -

RobotStudio Online.

Program messages

RAPID programs can send out messages to the Operator window, see section

Operator window on page 94

.

How to generate program messages is described in RAPID reference manual - Instructions.

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4 Navigating and handling FlexPendant

4.6.3. Scrolling and zooming on the FlexPendant

4.6.3. Scrolling and zooming on the FlexPendant

Overview

The entire contents of a screen may not be visible at the same time. To see the entire contents, you may:

•

Scroll up/down (and sometimes left/right)

• Zoom in or out (only available in the Program editor)

100 en0400000685

A

B

C

D

E

F

G

H

Zoom in (larger text)

Scroll up (the height of one page)

Scroll up (the height of one line)

Scroll left

Scroll right

Zoom out (smaller text)

Scroll down (the height of one page)

Scroll down (the height of one line)

3HAC 16590-1 Revision: B

4 Navigating and handling FlexPendant

4.6.4. Filtering data

4.6.4. Filtering data

Filtering data

In many of the FlexPendant’s menues you can filter data. This is useful e.g. when looking at instances of data types where there can be more available than is possible to overlook. By filtering out instances starting with a specific character, the number of choices can be reduced.

Illustration of filtering function

The filter function is switched on until the active filter is removed (using the keyboard).

en0500001539

Filter

Active filter

123 / ABC

Filter

Open or close the filtering function

Displays the current filter. This is also displayed in the top of the list of items

Switch between numeric or alphabetic keyboard

Applies the filter

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4 Navigating and handling FlexPendant

4.6.5. Process applications

4.6.5. Process applications

Process applications

Custom process applications are started from the ABB menu. Each application is listed as a menu item together with the FlexPendant’s views.

Start a process application

This procedure describes how to start a process application.

Step

1.

2.

Action

Tap the ABB button to display the ABB menu.

Process applications are listed in the menu.

Tap the name of the process application to start.

Switch between started process applications

A started application has a quick-button in the taskbar, just like FlexPendant views. Tap the buttons to switch between the started applications and views.

102 en0400000768

The views and process application running in this case are:

C

D

A

B

FlexPendant Explorer view

Program editor view

RobotWare Arc, a process application

Control panel view

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4 Navigating and handling FlexPendant

4.6.6. How to logout and login

4.6.6. How to logout and login

Logout procedure

The procedure details how to logout of the system.

Step

1.

2.

Action

Tap Logout on the ABB menu.

Tap Yes on the logout question.

Login procedure

The procedure details how to login to the controller, using the User Authorization System,

UAS. UAS can limit the available functions for users.

After a logout, the Login window automatically appears.

en0400000947

Step

1.

2.

3.

Action Info

Tap on the User menu to choose user.

If you tap Default User, no password is required, and you are logged in automatically.

If the user you have chosen has a password you must use the soft keyboard to enter password.

Tap ABC... to display the soft keyboard.

After entering the password tap OK.

Tap Login.

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4 Navigating and handling FlexPendant

4.6.6. How to logout and login

Continued

Handling users and authorization levels

Read more on how to add users or set the authorization in

Operator’s manual - RobotStudio

Online

.

How to edit what views or functions are hidden for certain users is described in

Configuring view settings on page 295

.

104 3HAC 16590-1 Revision: B

5 Jogging

5.1. Introduction to jogging

5 Jogging

5.1. Introduction to jogging

What is jogging?

To jog is to manually position or move robots or external axes using the FlexPendant joystick.

When can I jog?

You jog in manual mode. Jogging is possible regardless of what view is displayed on the

FlexPendant, however you cannot jog during program execution.

About motion modes and robots

The selected motion mode and/or coordinate system determines the way the robot moves.

In linear motion mode the tool center point moves along straight lines in space, in a “move from point A to point B” fashion. The tool center point moves in the direction of the selected coordinate system’s axes.

Axis-by-axis mode moves one robot axis at a time. It is then hard to predict how the tool center point moves.

About motion modes and additional axes

Additional axes can only be jogged axis-by-axis. An additional axis can either be designed for some kind of linear motion or for rotational (angular) motion. Linear motion is used in conveyers, rotational motion in many kinds of workpiece handlers.

Additional axes are not affected by the selected coordinate system.

About coordinate systems

Positioning a pin in a hole with a gripper tool can be performed very easily in the tool coordinate system, if one of the coordinates in that system is parallel to the hole. Performing the same task in the base coordinate system may require jogging in both x, y, and z coordinates, making precision much more difficult.

To select the proper coordinate systems to jog in will make jogging easier but there are no simple or single answers to which coordinate system to choose.

A certain coordinate system will make it possible to move the tool center point to the target position with fewer joystick moves than another.

Conditions such as space limitations, obstacles or the physical size of a work object or tool will also guide you to the proper judgement.

Read more about coordinate systems in section

What is a coordinate system? on page 305

.

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5 Jogging

5.2.1. Restrictions to jogging

5.2 Jogging concept

5.2.1. Restrictions to jogging

Jog additional axes

Additional axes can only be jogged axis-by-axis. Please see

Application manual - Additional axes

.

Jog mechanical units that are not calibrated

An uncalibrated mechanical unit can only be jogged axis-by-axis. Its working range will not be checked.

If the mechanical unit is not calibrated the text “Unit not calibrated” will be displayed in the

Position area of the Jogging window.

CAUTION!

Mechanical units whose working range is not controlled by the robot system can be moved to dangerous positions. Mechanical stops should be used and configured to avoid danger to equipment or personnel.

Jog robot axes in independent mode

It is not possible to jog axes in independent mode. You need to return the axes to normal mode in order to jog. Please see

Application manual - Motion functions and events

for details.

Jog while using world zones

With the option World Zones installed, defined zones will restrict motion while you jog.

Please see

Application manual - Motion functions and events

for details.

Jog with axis loads not set

If equipment is mounted on any of the robot axes, then axes loads must be set. Otherwise overload errors might occur when jogging.

How to set axis loads are described in the Product Manuals delivered with your robot.

Jog with tool or payload weights not set

If the weight of tools and payloads is not set, then overload errors might occur when jogging.

Loads for additional axes controlled by specific software (dynamic models) can only be set in programing.

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5 Jogging

5.2.2. Coordinated jogging

5.2.2. Coordinated jogging

Coordination

A robot that is coordinated to a work object will follow the movements of that work object.

Coordinated jogging

If the mechanical unit moving the work object is jogged, any robot that is currently coordinated with the work object will move so that it maintains its relative position to the work object.

Set up coordination

Step

1.

2.

3.

4.

Action Info

Select the robot that is to be coordinated to another mechanical unit.

See

Selecting mechanical unit on page

108

.

Set Coordinate system to Work

Object.

Set Work object to the work object moved by the other mechanical unit.

Select the mechanical unit that moves the work object.

See

See

Jog in work object coordinates on page 119

.

Selecting tool, work object, and payload on page 112

.

Any jogging, while this mechanical unit is selected, will also affect the robot that is coordinated with it.

Coordinating robots

Coordinating robots, so that when jogging one robot another robot will follow, requires the option MultiMove.

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5 Jogging

5.3.1. Selecting mechanical unit

5.3 Basic settings for jogging

5.3.1. Selecting mechanical unit

Examples of use

Your robot system may consist of more than a single robot. There can also be other mechanical units such as workpiece handlers or additional axes mounted on the robot that can also be jogged.

If your system only has a single robot without additional axes, then you do not need to select mechanical unit.

Identifying mechanical units

Each mechanical unit that can be jogged is represented in the mechanical units list. The name of the unit is defined in the system configuration. Each unit also has a symbol that is used in the Status bar, see section

Status bar on page 95

.

Please consult your plant or cell documentation to see which mechanical units are available in your robot system.

Selecting mechanical unit

This procedure describes how to select a mechanical unit to jog.

Step

1.

Action

On the ABB menu, tap Jogging.

108

Continues on next page

3HAC 16590-1 Revision: B

Step

2.

Action

Tap Mechanical Unit.

5 Jogging

5.3.1. Selecting mechanical unit

Continued

3.

en0400000653

A list of available mechanical units is displayed.

Tap the mechanical unit to be jogged, and then tap OK.

The selected mechanical unit is used until you choose another unit, even if you close the Jogging window.

TIP!

Use the QuickSet menu to switch between mechanical units faster.

How jogging properties apply

Any changes you make to jogging properties only affects the currently selected mechanical unit.

All jogging properties are saved and restored when you return to jog that mechanical unit.

Related information

Mechanical units can be activated or deactivated using the Activate function in the Jogging

menu, see section

Activating mechanical units on page 195

.

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5 Jogging

5.3.2. Selecting motion mode

5.3.2. Selecting motion mode

Overview

The Joystick Directions area shows how joystick axes correspond to the selected coordinate system’s axes.

CAUTION!

The Directions properties is not intended to show the direction in which the mechanical unit will move. Always try jogging with small joystick movements so that you learn the true directions of the mechanical unit.

Selecting motion mode

This procedure describes how to select motion mode.

Step

1.

2.

3.

Action Info

Tap ABB, then Jogging.

Tap Motion mode.

Tap on the mode you want and then tap

OK.

The significance of the joystick directions are shown in Joystick

direction after making the selection.

Joystick directions

The significance of the joystick directions depends on what motion mode has been selected.

The following are available:

Motion mode

Linear

Illustration joystick Description

Linear mode is described in

section

Setting the tool orientation on page 113

.

Axis 1-3

(default for robots) en0400001131

Axis 1-3 mode is described in section

Jog axis by axis on page

114

.

en0300000536

110

Continues on next page

3HAC 16590-1 Revision: B

Motion mode

Axis 4-6

Illustration joystick

Reorient en0300000537

5 Jogging

5.3.2. Selecting motion mode

Continued

Description

Axis 4-6 mode is described in section

Jog axis by axis on page

114

.

Reorient mode is described in

section

Setting the tool orientation on page 113

.

en0400001131

3HAC 16590-1 Revision: B 111

5 Jogging

5.3.3. Selecting tool, work object, and payload

5.3.3. Selecting tool, work object, and payload

Overview

It is always important to choose the proper tool, work object, or payload. It is absolutely vital when you create a program by jogging to the target positions.

Failing to do so will most likely result in overload errors and/or incorrect positioning either when you jog or when you run the program in production.

Selecting tool, work object, and payload

Step

1.

2.

3.

Action

On the ABB menu, choose Jogging to view jogging properties.

Tap Tool, Work object, or Payload to display the lists of available tools, work objects or payloads.

Tap the tool, work object, or payload of choice followed by OK.

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5 Jogging

5.3.4. Setting the tool orientation

5.3.4. Setting the tool orientation

Examples of use

Tools for arc welding, grinding and dispensing must be oriented in a particular angle to the work piece to obtain the best result. You also need to set up the angle for drilling, milling or sawing.

In most cases you set the tool orientation when you have jogged the tool center point to a specific position such as the starting point for a tool operation. After you have set the tool orientation you continue to jog in linear motion to complete the path and the supposed operation.

Definition of tool orientation

The tool orientation is relative to the currently selected coordinate system. From a user perspective however this is not noticeable.

Setting the tool orientation

Step

1.

2.

3.

4.

Action

On the ABB menu, tap Jogging.

Tap Motion Mode, then tap Reorient followed by OK.

If not already selected, select the proper tool by following the procedure in

Selecting tool, work object, and payload on page 112

.

Press and hold the enabling device to activate the mechanical unit’s motors.

Move the joystick and the tool’s orientation changes.

TIP!

Use the QuickSet menu to select jogging mode faster.

3HAC 16590-1 Revision: B 113

5 Jogging

5.3.5. Jog axis by axis

5.3.5. Jog axis by axis

Examples of use

Select axes to move

Use axis by axis jogging when you need to:

• move the mechanical unit out of hazardous positions.

• move a robot out of singularities.

• position a robot’s axes for calibration.

Step

1.

2.

3.

4.

Action

On the ABB menu, tap Jogging to view jogging properties.

Tap Motion Mode, then select the appropriate axes, see description in

Illustration of axes and joystick directions on page 114

.

Tap OK to complete.

Press the enabling device and jog the axes.

Illustration of axes and joystick directions

The regular six axes of a generic manipulator may be jogged manually using the three dimensions of the joystick as specified below. Please check your plant or cell documentation to determine the physical orientation of any additional axes.

The illustration shows the movement patterns of the manipulator's axes.

114 xx0300000520

Continues on next page

3HAC 16590-1 Revision: B

5 Jogging

5.3.5. Jog axis by axis

Continued

If you want to move… then tap…

axis 1, 2 or 3

for joystick directions…

en0300000534 en0300000536 axis 4, 5 or 6 en0300000535 en0300000537

CAUTION!

The orientation of any mounted tool will be affected by this procedure. If the resulting orientation is important, perform the procedure described in

Setting the tool orientation on page 113

when finished.

3HAC 16590-1 Revision: B 115

5 Jogging

5.3.6. Jog in base coordinates

5.3.6. Jog in base coordinates

Base coordinates definition

xx0300000495

Jog in base coordinates

Step

1.

2.

3.

4.

5.

Action

On the ABB menu, tap Jogging to view jogging properties.

Tap Motion Mode, then tap Linear followed by OK.

You don’t need to perform this step if you previously selected linear motion.

Tap Coordinate System, then tap Base followed by OK.

Press and hold the enabling device to activate the manipulator’s motors.

Move the joystick and the mechanical unit moves along.

TIP!

Use the QuickSet menu to select jogging mode faster.

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5 Jogging

5.3.7. Jog in world coordinates

5.3.7. Jog in world coordinates

Examples of use

For example, you have two robots, one floor mounted and one inverted. The base coordinate system for the inverted robot would be upside down.

If you jog in the base coordinate system for the inverted robot, movements will be very difficult to predict. Choose the shared world coordinate system instead.

World coordinates definition

en0300000496

A

B

C

Base coordinate system

World coordinate system

Base coordinate system

3HAC 16590-1 Revision: B

Continues on next page

117

5 Jogging

5.3.7. Jog in world coordinates

Continued

Jog in world coordinates

Step

1.

2.

3.

4.

5.

Action

On the ABB menu, tap Jogging to view jogging properties.

Tap Motion Mode, then tap Linear followed by OK.

You don’t need to perform this step if you previously selected linear motion.

Tap Coordinate system, then tap World followed by OK.

Press and hold the enabling device to activate the manipulator’s motors.

Move the joystick and the mechanical unit moves along.

TIP!

Use the QuickSet menu to select jogging mode faster.

118 3HAC 16590-1 Revision: B

5 Jogging

5.3.8. Jog in work object coordinates

5.3.8. Jog in work object coordinates

Examples of use

For example, you are determining the positions of a number of holes to be drilled along the edge of the work object.

You are creating a weld between two walls in a box.

Work object coordinates definition

en0300000498

A

B

C

D

User coordinate system

World frame

Work object coordinate system

Work object coordinate system

Jog in work object coordinates

Step

1.

2.

3.

4.

5.

6.

Action

On the ABB menu, tap Jogging to view jogging properties.

Tap Motion Mode, then tap Linear followed by OK.

This is not required if you previously selected linear motion.

Tap Work object to select work object..

Tap Coordinate system, then tap Work Object followed by OK.

Press and hold the enabling device to activate the manipulator’s motors.

Move the joystick and the mechanical unit moves along.

TIP!

Use the QuickSet menu to select jogging mode faster.

3HAC 16590-1 Revision: B 119

5 Jogging

5.3.9. Jog in tool coordinates

5.3.9. Jog in tool coordinates

Examples of use

Use the tool coordinate system when you need to program or adjust operations for threading, drilling, milling or sawing.

Tool coordinates definition

The tool coordinate system has its zero position at the center point of the tool. It thereby defines the position and orientation of the tool. The tool coordinate system is often abbreviated to TCP (Tool Center Point) or TCPF (Tool Center Point Frame).

When jogging a robot the tool coordinate system is useful when you don’t want to change the orientation of the tool during the movement, for instance moving a saw blade without bending it.

en0300000497

Jog in tool coordinates

Step

1.

2.

3.

4.

5.

6.

Action

On the ABB menu, tap Jogging to view jogging properties.

Tap Motion mode, then tap Linear followed by OK.

You do not need to perform this step if you previously selected linear motion.

Select the proper tool, and if using a stationary tool the proper work object by

following the procedure in

Selecting tool, work object, and payload on page 112

.

You do not need to perform this step if you previously selected the tool and/or work object.

Tap Coordinate System, then tap Tool followed by OK.

Press and hold the enabling device to activate the mechanical unit’s motors.

Move the joystick and the mechanical unit moves along.

120

Continues on next page

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5 Jogging

5.3.9. Jog in tool coordinates

Continued

TIP!

Use the QuickSet menu to select jogging mode faster.

Jog with a stationary tool

If your robot system uses stationary tools, you must select both the proper tool and the proper work object (held by the robot) to jog in tool coordinates.

The tool coordinate system is defined by the position and orientation of the stationary tool and is fixed in space. To perform the intended operations you move the work object. This way positions can be expressed in the tool coordinate system.

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5 Jogging

5.3.10. Locking the joystick in specific directions

5.3.10. Locking the joystick in specific directions

Overview

The joystick can be locked in specific directions to prevent movement for one or more axes.

This may be useful for instance while fine tuning positions or when programming operations that should only be performed in the direction of a specific coordinate system axis.

Note that the axes locked depends on the currently selected motion mode.

Which axes are locked?

This section describes how to see which joystick directions are locked

Step

1.

2.

Action

On the ABB menu, tap Jogging to view jogging properties.

Tap Joystick lock to check the joystick properties, or check the Joystick

directions area properties in the right hand corner of the window.

A padlock symbol is displayed for locked axes.

Locking the joystick in specific directions

This section describes how to lock the joystick in specific directions.

Step

1.

2.

Action

In the ABB menu, tap Jogging.

Tap Joystick lock.

122

3.

4.

en0300000488

Tap the joystick axis or axes that should be locked.

The axis toggles between locked and unlocked each time you tap.

Tap OK to lock.

Continues on next page

3HAC 16590-1 Revision: B

5 Jogging

5.3.10. Locking the joystick in specific directions

Continued

Unlocking all axes

This section describes how to unlock all axes from the joystick directions lock.

Step

1.

2.

3.

Action

In the ABB menu, tap Jogging.

Tap Joystick lock.

Tap None, then tap OK.

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5 Jogging

5.3.11. Incremental movement for precise positioning

5.3.11. Incremental movement for precise positioning

Incremental movement

Use incremental movement to jog the robot in small steps, which enables very precise positioning.

This means that each time the joystick is deflected, the robot moves one step (increment). If the joystick is deflected for one or more seconds, a sequence of steps, (at a rate of 10 steps per second), will be performed as long as the joystick is deflected.

Default mode is no increment, then the robot moves continuously when the joystick is deflected.

Set the incremental movement size

This procedure details how to specify the size of the incremental movement.

Step

1.

2.

Action

In the ABB menu, tap Jogging.

Tap Increment.

124

3.

4.

en0400000971

Tap the desired increment mode, see description in section

Incremental movement sizes on page 125

.

Tap OK.

Continues on next page

3HAC 16590-1 Revision: B

5 Jogging

5.3.11. Incremental movement for precise positioning

Continued

Incremental movement sizes

Choose between small, medium or large increments. You can also define your own increment movement sizes.

Increment

Small

Medium

Large

User

Distance

0.05 mm

1 mm

5 mm

Angular

0.005°

0.02°

0.2°

3HAC 16590-1 Revision: B 125

5 Jogging

5.3.12. How to read the exact position

5.3.12. How to read the exact position

How robot positions are displayed

Positions are always displayed as:

• the point in space expressed in the x, y and z tool center point coordinates,

• the angular rotation of the tool center point expressed in Euler angles or as a quaternion.

How additional axes’ positions are displayed

When an additional axis is moved, only the axis position is displayed.

Linear axis positions are displayed in millimeters expressed as the distance to the calibration position.

Rotating axis positions are displayed in degrees expressed as the angle to the calibration position.

No positions displayed

No position is displayed when the mechanical unit is uncalibrated. Instead the text “Unit not calibrated" is displayed.

How to read the exact position

This procedure describes how to read the exact position.

Step

1.

2.

Action

On the ABB menu tap Jogging.

The position is displayed in the Position area properties in the right hand side of the window.

See illustration in

Jogging on page 77

.

Illustration of position format

The illustration shows all available settings for showing the position format:

126

Continues on next page

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5 Jogging

5.3.12. How to read the exact position

Continued

en0400000991

Available selections for position format

The following selections are available for Position shown in

Illustration of position format on page 126

:

•

World

• Base

•

Work object

The following selections are available for Orientation format:

•

Quaternion

• Euler angles

The following selections are available for Position angle format:

• Angles

The following selections are available for Presentation angle unit:

• Degrees

•

Radians

3HAC 16590-1 Revision: B 127

5 Jogging

5.3.13. Quickset menu, Mechanical unit

5.3.13. Quickset menu, Mechanical unit

Mechanical unit button

Step

1.

Action

On the Quickset menu, tap Mechanical unit, then tap to select a mechanical unit.

128 en0300000539

The following buttons are displayed:

• A: Mechanical unit menu button

• B: Mechanical unit, a selected unit is highlighted

• C: Motion mode settings

• D: Tool settings

• E: Work object settings

• F: Coordinate system settings

Each button is described in the following steps.

Continues on next page

3HAC 16590-1 Revision: B

5 Jogging

5.3.13. Quickset menu, Mechanical unit

Continued

Step

2.

Action

If you want to view/change any motion mode functionality, tap the Motion mode settings button.

en0300000540

The following buttons are displayed:

• A: Axes 1-3 motion mode

• B: Axes 4-6 motion mode

• C: Linear motion mode

• D: Reorient motion mode

• E: Close motion mode settings

3HAC 16590-1 Revision: B

Continues on next page

129

5 Jogging

5.3.13. Quickset menu, Mechanical unit

Continued

Step

3.

Action

If you want to view/change the available tools, tap the Tool settings button.

4.

en0400000988

A list of all available, defined tools is shown. Tap the one to use.

If you want to view/change the available work objects, tap the Work object settings button.

130 en0400000989

A list of all available, defined work objects is shown. Tap the one to use.

Continues on next page

3HAC 16590-1 Revision: B

5 Jogging

5.3.13. Quickset menu, Mechanical unit

Continued

Step

5.

Action

If you want to view/change any Coordinate system functionality, tap the

Coordinate system settings button.

en0300000541

The following buttons are displayed:

• World coordinate system

• Base coordinate system

• Tool coordinate system

• Work object coordinate system

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5 Jogging

5.3.14. Quickset menu, Increment

5.3.14. Quickset menu, Increment

Increment

All functions under this button may also be reached from the Jogging menu.

Step

1.

Action

If you want to view/change any increment functionality, tap the increment button.

132 en0300000542

Tap to select increment size:

• None for no increments

• Small movement increments

• Medium movement increments

• Large movement increments

• User for movement increments defined by the user.

Tap Show values to display the increment values.

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6 Programming and testing

6.1. Before you start programming

6 Programming and testing

6.1. Before you start programming

Programming tools

You can use both the FlexPendant and RobotStudio

Online

for programming. For basic programming it may be easier to use RobotStudio

Online

, while the FlexPendant is best suited for modifying programs, such as positions and paths.

How to program using RobotStudio

Online

is described in Operator’s manual - RobotStudio

Online.

Define tools, payloads and work objects

Define tools, payloads and work objects before you start programming. You can always go back and define more objects later, but you should define your basic objects in advance.

Define coordinate systems

Make sure the base and world coordinate systems have been set up properly during the installation of your robot system. Also make sure that additional axes have been set up.

Define tool and work object coordinate systems as needed before you start programming. As you add more objects later you also need to define the corresponding coordinate systems.

TIP!

Need to know more about the RAPID language and structure? See the manuals RAPID

reference manual - RAPID overview, RAPID reference manual - Instructions, and RAPID

reference manual - Functions and data types.

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6 Programming and testing

6.2.1. The structure of a RAPID application

6.2 Programming concept

6.2.1. The structure of a RAPID application

Illustration of a RAPID application

The structure and contents of the main computer RAM memory during operation is described in section

The structure of the main computer RAM memory contents on page 249

Parts

134 en0300000576

Part

Task

Task property parameter

Program

Function

Each task usually contains a RAPID program and system modules aimed at performing a certain function, e.g. spot welding or manipulator movements.

A RAPID application may contain one task. If you have the Multitasking option installed, then there can be more than one task.

Read more about Multitasking in

Application manual - Engineering tools

.

The task property parameters set certain properties for all task contents.

Any program stored in a certain task, assumes the properties set for that task.

The task property parameters are specified in

RAPID reference manual

.

Each program usually contains program modules with RAPID code for different purposes.

Any program must have an entry routine defined to be executable.

Continues on next page

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6 Programming and testing

6.2.1. The structure of a RAPID application

Continued

Part

Program module

Data

Routine

Entry routine

Function

Each program module contains data and routines for a certain purpose.

The program is divided into modules mainly to enhance overview and facilitate handling the program. Each module typically represents one particular robot action or similar.

All program modules will be removed when deleting a program from the controller program memory.

Program modules are usually written by the user.

Data are values and definitions set in program or system modules. The data are referenced by the instructions in the same module or in a number of modules (availability depending on data type).

Data type definitions are specified in the

RAPID reference manual,

Functions and data types

.

A routine contains sets of instructions, i.e. defines what the robot system actually does.

A routine may also contain data required for the instructions.

A special type of routine, in English sometimes referred to as "main", defined as the program execution starting point.

Note

Each program must have an entry routine called "main", or it will not be executable. How to appoint a routine as entry routine is specified in

RAPID reference manual

. The default name for main can be changed by the system parameter configurations, type Task. See Technical reference

manual - System parameters.

Instruction Each instruction is a request for a certain event to take place, e.g. "Run the manipulator TCP to a certain position" or "Set a specific digital output".

The instructions, their syntax and function is thoroughly described in the

RAPID reference manual, Instructions

.

System module Each system module contains data and routines to perform a certain function.

The program is divided into modules mainly to enhance overview and facilitate handling the program. Each module typically represents one particular robot action or similar.

All system modules will be retained when "Delete program" is ordered.

System modules are usually written by the robot manufacturer or line builder.

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6 Programming and testing

6.3.1. Viewing data in specific tasks, modules, or routines

6.3 Data types

6.3.1. Viewing data in specific tasks, modules, or routines

Overview

It is possible to view selections of data types by selecting a specific scope.

Viewing data in specific tasks, modules, or routines

This section details how to view data instances in specific modules or routines.

Step

1.

2.

Action

In the ABB menu, tap Program Data.

Tap Change Scope.

The following screen is displayed:

136

3.

4.

5.

en0400000661

Select the required scope by selecting:

• Built-In Data Only: Shows all data types used by the specific system

• Task: Shows all data types used by a specific task

• Module: Shows all data types used by a specific module

• Routine: Shows all data types used by a specific routine

Tap OK to confirm your choice.

Tap twice to select a data type and view its instances.

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6 Programming and testing

6.3.2. Creating new data instance

6.3.2. Creating new data instance

Creating new data instance

This section details how to create new data instances of data types.

Step

1.

2.

3.

Action

In the ABB menu, tap Program Data.

A list of all available data types is displayed.

Tap the data instance type to be created, i.e. bool and then tap Show data.

A list of all instances of the data type is displayed.

Tap New.

4.

5.

6.

7.

8.

en0400000663

Tap ... the right of Name to define the data instance’s name.

Tap the Scope menu to set accessibility for the data instance. Select:

•

Global

•

Local

•

Task

Tap the Storage type menu to select type of memory used for the data instance.

Select:

• Persistent if the data instance is persistent

• Variable if the data instance is variable

• Constant if the data instance is constant

Tap the Module menu to select module.

Tap the Routine menu to select routine.

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6 Programming and testing

6.3.2. Creating new data instance

Continued

Step Action

9.

If you want to create an array of data instances, then tap the Dimensions menu and select the number of dimensions in the array, 1-3.

• 1

• 2

• 3

• None

Then tap ... to set the Size of the array’s axes.

Arrays are described in section

What is a data array? on page 312

10.

Tap OK.

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6 Programming and testing

6.3.3. Editing data instances

6.3.3. Editing data instances

Overview

This section describes how to view data instances and then edit values, delete, change declaration of, copy, or define an instance.

For instances of the types tooldata, wobjdata, and loaddata, see sections

Tools on page 142

,

Work objects on page 154

, or

Payloads on page 161

.

Viewing data instances

This section details how to view the available instances of a data type.

Step

1.

2.

3.

Action

In the ABB menu, tap Program Data.

Tap the data type of the instance you want view, and then tap Show Data.

Tap and hold the data instance for a couple of seconds.

A circle of red dots and a menu appears.

4.

en0400000671

Depending on what you want to do with the data instance, you have the following choices:

• Tap Delete to remove the data instance.

• Tap Change Declaration to change the declaration of the data instance.

• Tap Copy to copy the data instance.

• Tap Define to define the tool frame (only available for tool, work object, and load data).

Proceed as described in the following sections.

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6 Programming and testing

6.3.3. Editing data instances

Continued

Editing data instance values

This section describes how to edit a data instance value..

Step

1.

2.

3.

4.

Action Info

Tap Edit value to open the instance.

Tap the value to open a keyboard or list of choices.

The way to edit values depend on the data type and possible values, for instance text, numbers, predefined values etc.

Select or enter a new value.

Tap OK.

Deleting data instances

This section details how to delete data instances.

Step

1.

2.

Action

Tap Delete in the menu for the data instance to be deleted, as detailed in section

Viewing data instances on page 139

.

A dialog box is displayed.

Tap Yes if you are sure the data instance is to be deleted.

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Continues on next page

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6 Programming and testing

6.3.3. Editing data instances

Continued

Changing data instance declarations

This section details how to change the declaration of the data instances.

Step

1.

Action

Tap Change declaration in the menu for the data instance to be deleted, as detailed in section

Viewing data instances on page 139

.

2.

en0400000672

Select what data instance values to be changed:

• Name: Tap ... to bring out the soft keyboard and change the name.

• Scope

• Storage type

• Module

• Routine

Copying data instances

This section details how to copy the data instances.

Step

1.

Action

Tap Copy in the menu for the data instance to be copied, as detailed in section

Viewing data instances on page 139

.

A copy of the data instance is created.

The copy has the same values as the original, but the name is unique.

Defining data instances

How to define tool frame or work object frame is described in sections

Defining the tool frame on page 145

or

Defining the work object coordinate system on page 155

.

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6 Programming and testing

6.4.1. Creating a tool

6.4 Tools

6.4.1. Creating a tool

What happens when I create a tool?

A variable of the type tooldata

is created. The variable’s name will be the name of the tool.

For more information on data types, see RAPID reference manual - Functions and data types.

The new tool has default values for weight etc which must be defined before the tool can be used.

Creating a tool

The tool center point of the default tool (tool0) is in the center of the robot’s mounting flange and with the mounting flange’s orientation.

By creating a tool you can define another tool center point.

142 en0400000779

A Tool center point, TCP, for tool0

Step

1.

2.

Action

On the ABB menu, tap Jogging.

Tap Tool to display the list of available tools.

A

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Step

3.

Action

Tap New... to create a new tool.

6 Programming and testing

6.4.1. Creating a tool

Continued

4.

en0300000544

Enter values for each field, see table below.

Tap OK.

Tool declaration settings

If you want to change...

then...

the tool’s name tap the ... button next to the name the scope the storage type select the scope of choice from the menu

Recommendation

Tools are automatically named tool

followed by a running number, for example tool10

or tool21

.

You should change this to something more descriptive such as gun, gripper or welder.

If you change the name of a tool after it is referenced in any program you must also change all occurrences of that tool.

Tools should always be global to be available to all modules in the program.

Tool variables must always be persistent.

the module select the module in which this tool should be declared from the menu

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6 Programming and testing

6.4.1. Creating a tool

Continued

NOTE!

The created tool is not useful until you have defined the tool data (TCP coordinates, weight etc.). This can be done by running the service routine LoadIdentify, or by editing the values manually. See

LoadIdentify, load identifiction service routine on page 214

or

Editing the tool data on page 148

.

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6 Programming and testing

6.4.2. Defining the tool frame

6.4.2. Defining the tool frame

Preparations

To define the tool frame, you first need a reference point in the world coordinate system. If you need to set the tool center point orientation, you also need to affix elongators to the tool.

Selecting method for defining tool frame

This procedure describes how to select method for defining the tool frame.

Step

1.

2.

3.

4.

5.

6.

Action

On the ABB menu, tap Jogging.

Tap Tool to display the list of available tools.

Tap and hold the tool you want to define.

A menu appears.

In the menu, tap Define...

The tool coordinate system definition dialog box appears.

Select the method of choice from the Method pop up menu.

Select the number of approach points from the No of points pop up menu.

Available methods

All methods require you to define the cartesian coordinates of the tool center point. The methods give you a choice in how the orientation will be set and defined.

If you want to...

...then select

set the orientation the same as the orientation of the robots mounting plate

4 points TCP keep the current orientation set the orientation in Z axis set the orientation in X and Z axes

4 points TCP (orientation unchanged)

5 points TCP & Z

6 points TCP & Z, X

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6 Programming and testing

6.4.2. Defining the tool frame

Continued

Defining tool center point Cartesian coordinates

This procedure describes how to define the tool center point in Cartesian coordinates.

146 en0400000906

Step

1.

2.

3.

Action Info

Jog the robot to an appropriate position for the first approach point.

Position A

Tap Modify Position to define the point.

Repeat step 1 and 2 for each approach point to be defined, positions B, C, and D.

Jog away from the fixed world point to achieve best results. Just changing the tool orientation will not give as good a result.

Continues on next page

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6 Programming and testing

6.4.2. Defining the tool frame

Continued

Defining elongator points

This procedure describes how to define the elongator points.

Step

1.

2.

3.

Action

Without changing the tool’s orientation, jog the robot so that the fixed world point becomes a point on the desired positive axis of the rotated tool coordinate system.

Tap Modify Position to define the point.

Repeat step 1 and 2 for the second axis if it also should be defined.

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6 Programming and testing

6.4.3. Editing the tool data

6.4.3. Editing the tool data

Tool data

Use the value settings to set the tool center point position and physical properties of the tool such as weight and center of gravity.

This can also be done automatically with the service routine LoadIdentify. See sections

Running a service routine on page 209

, or

LoadIdentify, load identifiction service routine on page 214

.

Displaying the tool data

This section details how to display the tool data.

Step

1.

2.

3.

4.

5.

Action

On the ABB menu, tap Jogging.

Tap Tool to display the list of available tools.

Tap and hold the tool you want to edit.

A menu appears.

• Change Declaration

• Change Value

• Delete

• Define

In the menu, tap Change Value.

The data that defines the tool appears. Green text indicates that the value can be changed.

Proceed with changing the data as described below.

Measuring the tool center point

The easiest way to define the tool center point, TCP, is usually to use the predefined method described in

Defining the tool frame on page 145

. If you use this method, you do not have to

write any values for tframe as these are supplied by the method.

If you already have the measurements of the tool, or for some reason want to measure them manually, the values can be entered in the tool data.

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6 Programming and testing

6.4.3. Editing the tool data

Continued

X

1

Y

1

Z

1

X

0

Y

0

Z

0

X axis for tool0

Y axis for tool0

Z axis for tool0

X axis for the tool you want to define

Y axis for the tool you want to define

Z axis for the tool you want to define

Step

1.

2.

3.

Action

Measure the distance from the center of the robot’s mounting flange to the tool’s center point along the X axis of tool0.

Measure the distance from the center of the robot’s mounting flange to the tool’s center point along the Y axis of tool0.

Measure the distance from the center of the robot’s mounting flange to the tool’s center point along the Z axis of tool0.

Editing the tool definition

Step

1.

2.

3.

4.

5.

6.

7.

Action Instance

Enter the cartesian coordinates of the tool center point’s position.

tframe.trans.x

tframe.trans.y

tframe.trans.z

If necessary, enter the tool frame orientation.

tframe.rot.q1

tframe.rot.q2

tframe.rot.q3

tframe.rot.q4

Enter the weight of the tool.

tload.mass

If necessary, enter the tool’s center of gravity.

tload.cog.x

tload.cog.y

tload.cog.z

If necessary, enter the orientation of the axis of moment tload.aom.q1

tload.aom.q2

tload.aom.q3

tload.aom.q4

If necessary, enter the tool’s moment of inertia.

tload.ix

tload.iy

tload.iz

Tap OK to use the new values,

Cancel to leave the definition unchanged.

Unit

[mm]

None

[kg]

[mm]

None

[kgm

2

]

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6 Programming and testing

6.4.4. Editing the tool declaration

6.4.4. Editing the tool declaration

Tool declaration

Use the declaration to change how the tool variable can be used in the program’s modules.

Displaying the tool declaration

Step

1.

2.

3.

4.

Action

On the ABB menu, tap Jogging.

Tap Tool to see the list of available tools.

Tap and hold the tool whose definition you want to edit.

A menu appears.

• Change Declaration

• Change Value

• Delete

• Define

In the menu, tap Change Declaration.

The tool's declaration appears.

Edit the tool declaration as listed in section

Creating a tool on page 142

.

5.

NOTE!

If you change the name of a tool after it is referenced in any program you must also change all occurrences of that tool.

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6 Programming and testing

6.4.5. Deleting a tool

6.4.5. Deleting a tool

Deleting a tool

This section describes how to delete a tool.

Step

1.

2.

3.

4.

5.

Action

In the ABB menu, tap Jogging.

Tap Tool to display the list of available tools.

Tap and hold the tool you want to delete.

A menu appears.

Tap Delete to delete the selected tool.

A confirmation dialog box appears.

In the dialog box, tap Yes to delete the tool, No to keep the tool.

CAUTION!

A deleted tool, work object or payload cannot be recovered, and all related data will be lost.

If the tool, work object or payload is referenced by any program, those programs cannot run without changes.

If you delete a tool you cannot continue the program from the current position.

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6 Programming and testing

6.4.6. Setup for stationary tools

6.4.6. Setup for stationary tools

Stationary tools

Stationary tools are used, for instance, in applications that involve large machines such as cutters, presses and punch cutters. You may use stationary tools to perform any operation that would be difficult or inconvenient to perform with the tool on the robot.

With stationary tools, the robot holds the work object.

Make a tool stationary

This section describes how to make a tool stationery.

Step

1.

2.

3.

4.

5.

6.

7.

Action

In the ABB menu, tap Jogging.

Tap Tool to display the list of available tools.

Tap and hold the tool you want to edit.

A menu appears.

In the menu, tap Change value.

The data that defines the tool appears.

Tap the instance robhold

.

Tap FALSE to make this tool stationary.

Tap OK to use the new setup, Cancel to leave the tool unchanged.

Make a work object robot held

This section describes how to make a work object robot held.

Step

1.

2.

3.

4.

5.

6.

Action

In the Jogging window, tap Work object to display the list of available work objects.

Tap and hold the work object you want to edit.

A menu appears.

In the menu, tap Change value.

The data that defines the work object appears.

Tap the instance robhold

.

Tap TRUE to indicate that this work object is held by the robot.

Tap OK to use the new setup, Cancel to leave the work object unchanged.

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6.4.6. Setup for stationary tools

Continued

Differences in coordinate system referencing

This section describes differences in coordinate system referencing.

The...

work object coordinate system user coordinate system tool coordinate system

...normally references the...

user coordinate system world coordinate system robot’s mounting plate

...but now references the...

user coordinate system (no change) robot’s mounting plate world coordinate system

Set up the tool coordinate system

You use the same measurement methods to set up a stationary tool coordinate system as with tools mounted on the robot.

The world reference tip must, in this case, be attached to the robot. Define and use a tool with the reference tip’s measurements when you create approach points. You also need to attach elongators to the stationary tool if you need to set up the orientation.

You should enter the reference tip’s tool definition manually to minimize errors when calculating the stationary tool’s coordinate system.

You may enter the stationary tool’s definition manually.

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6 Programming and testing

6.5.1. Creating a work object

6.5 Work objects

6.5.1. Creating a work object

What happens when I create a work object?

A variable of the type wobjdata

is created. The variable’s name will be the name of the work object.For more information on data types, see RAPID reference manual - Functions and data

types.

See also

What is a work object? on page 304

for more details.

Creating a work object

The work object’s coordinate system is now identical with the world coordinate system. To

define the position and orientation of the work object’s coordinate system, see Editing the work object data on page 158

Step

1.

2.

3.

4.

Action

On the ABB menu, tap Jogging.

Tap Work Object to display the list of available work objects.

Tap New... to create a new work object.

Tap OK.

Work object declaration settings

If you want to change...

then...

the work object’s name tap the ... button next to it the scope the storage type select the scope of choice from the menu

Recommendation

Work objects are automatically named wobj followed by a running number, for example wobj10

, wobj27

.

You should change this to something more descriptive.

If you change the name of a work object after it is referenced in any program you must also change all occurrences of that work object.

Work objects should always be global to be available to all modules in the program.

Work object variables must always be persistent.

the module select the module in which this work object should be declared from the menu

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6 Programming and testing

6.5.2. Defining the work object coordinate system

6.5.2. Defining the work object coordinate system

Overview

A work object must be defined in two frames, the user frame (related to the world frame) and the object frame (related to the user frame).

When defining a work object you can use either the user frame or the object frame.

Selecting method

This procedure describes how to select method. Note that this only works for a user created work object, not the default work object, wobj0.

Step

1.

2.

3.

4.

5.

Action

On the ABB menu, tap Jogging.

Tap Work object to display the list of available work objects.

Tap and hold the work object you want to define.

A menu appears.

In the menu, tap Define....

Select method from the User method or the Object method menu. See

Defining the user frame on page 156

and

Defining the work object frame on page 157

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6 Programming and testing

6.5.2. Defining the work object coordinate system

Continued

Defining the user frame

This section details how to define the user frame. Note that this only works for a user created work object, not the default work object, wobj0.

156 en0400000887

The x axis will go through points X1-X2, and the y axis through Y1.

Step

1.

2.

3.

4.

5.

Action Info

In the User method pop up menu, tap 3 points.

Press the enabling device and jog the robot to the first

(X1, X2 or Y1) point you want to define.

Great distance between

X1 and X2 is preferable for a more precise definition.

Select the point in the list.

Tap Modify Position to define the point.

Repeat steps 2 to 4 for the remaining points.

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6 Programming and testing

6.5.2. Defining the work object coordinate system

Continued

Defining the work object frame

This section describes how to define the work object frame.

en0400000899

The x axis will go through points X1-X2, and the y axis through Y1.

Step

1.

2.

Action

In the Object method pop up menu, tap 3 points.

See steps 2 to 4 in the description of

Defining the user frame on page 156

.

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6 Programming and testing

6.5.3. Editing the work object data

6.5.3. Editing the work object data

Overview

Use the definition to set the position of the user and work object coordinate system and physical properties of the work object, such as weight and center of gravity.

Displaying the work object data

Step

1.

2.

3.

4.

Action

In the ABB menu, tap Jogging.

Tap Work object to display the list of available work objects.

Tap and hold the work object you want to edit.

A menu appears.

In the menu, tap Change Value.

The data that defines the work object appears.

Setting the work object and user coordinate systems position

The easiest way to set the work object and user coordinate systems position is to use the

method described in

Defining the work object coordinate system on page 155

.

Step

1.

2.

3.

4.

5.

Action Instance

Enter the cartesian coordinates of the position of the work object coordinate system.

oframe.trans.x

oframe.trans.y

oframe.trans.z

If necessary, enter the coordinate system’s orientation.

oframe.rot.q1

oframe.rot.q2

oframe.rot.q3

oframe.rot.q4

Enter the cartesian coordinates of the position of the user coordinate system.

uframe.trans.x

uframe.trans.y

uframe.trans.z

If necessary, enter the coordinate system’s orientation.

uframe.rot.q1

uframe.rot.q2

uframe.rot.q3

uframe.rot.q4

Tap OK to user the new values,

Cancel to leave the definition unchanged.

-

-

-

Unit

[mm]

[mm]

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6 Programming and testing

6.5.4. Editing the work object declaration

6.5.4. Editing the work object declaration

Overview

Use the declaration to change how the work object variable can be used in the program’s modules.

Displaying the work object declaration

Step

1.

2.

3.

4.

5.

6.

Action

In the ABB menu, tap Jogging.

Tap Work object to see the list of available work objects.

Tap and hold the work object who’s definition you want to edit.

A menu appears.

In the menu, tap Change Declaration.

The work object’s declaration appears.

Edit the tool declaration as listed in section

Creating a work object on page 154

.

NOTE!

If you change the name of a work object after it is referenced in any program you must also change all occurrences of that work object.

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6 Programming and testing

6.5.5. Deleting a work object

6.5.5. Deleting a work object

Deleting a work object

Step

1.

2.

3.

4.

5.

Action

In the ABB menu, tap Jogging.

Tap Work object to display the list of available work objects.

Tap and hold the work object you want to delete.

A menu appears.

In the menu, tap Delete to delete the work object.

A confirmation dialog box appears.

In the dialog box, tap Yes to delete the work object, No to keep it.

CAUTION!

A deleted tool, work object or payload cannot be recovered, and all related data will be lost.

If the tool, work object or payload is referenced by any program, those programs cannot run without changes.

If you delete a tool you cannot continue the program from the current position.

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6 Programming and testing

6.6.1. Creating a payload

6.6 Payloads

6.6.1. Creating a payload

What happens when I create a payload?

A variable of the type loaddata

is created. The variables name will be the name of the payload. For more information on data types, see RAPID reference manual - Functions and

data types.

Adding a new payload and setting data declaration

The payloads coordinate system will be set to the position, including orientation, of the world coordinate system.

Step Action

1

2

3

In the ABB menu tap Jogging.

Tap Payload to display the list of available payloads.

Tap New to create a new payload. Enter data, see table below.

Tap OK.

Payload declaration settings

If you want to change...

the payload’s name the scope the storage type the module

-

...then...

tap the ... button next to it select the scope of choice from the menu select the module in which this payload should be declared from the menu

Recommendation

Payloads are automatically named load

followed by a running number, for example load10

, load31

.

You should change this to something more descriptive.

If you change the name of a payload after it is referenced in any program you must also change all occurrences of that payload’s name.

Payloads should always be global to be available to all modules in the program.

-

Payload variables must always be persistent.

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6 Programming and testing

6.6.2. Editing the payload data

6.6.2. Editing the payload data

Overview

Use the payload data to set physical properties of the payload such as weight and center of gravity.

This can also be done automatically with the service routine LoadIdentify. See sections

Running a service routine on page 209

, or

LoadIdentify, load identifiction service routine on page 214

.

Displaying the payload definition

Step

1.

2.

3.

4.

Action

In the ABB menu, tap Jogging.

Tap Payload to display the list of available payloads.

Tap and hold the payload you want to edit.

A menu appears.

On the menu, tap Change Value.

The data that defines the payload appears.

Changing the payload data

This procedure describes how to manually enter the payload data. This can also be done automatically by running the service routine Load Identify. How to run a service routine is described in section

Running a service routine on page 209

.

Step

1.

2.

3.

4.

5.

Action Instance

Enter the weight of the payload.

Enter the orientation of the axis of moment.

load.mass

Enter the payload’s center of gravity.

load.cog.x

load.cog.y

load.cog.z

load.aom.q1

load.aom.q2

load.aom.q3

load.aom.q3

Enter the payload’s moment of inertia.

ix iy iz

Tap OK to use the new values, Cancel to leave the data unchanged.

-

Unit

[kg]

[mm]

[kgm

2

]

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6 Programming and testing

6.6.3. Editing the payload declaration

6.6.3. Editing the payload declaration

Overview

Use the declaration to change how the payload variable can be used in the program’s modules.

Displaing the payload declaration

Step

1.

2.

3.

4.

5.

Action

In the ABB menu, tap Jogging.

Tap Payload to see the list of available payloads.

Tap and hold the payload whose definition you want to edit.

A menu appears.

In the menu, tap Change declaration.

The payload’s declaration appears. See

Creating a payload on page 161

.

NOTE!

If you change the name of a payload after it is referenced in any program you must also change all occurrences of that payload’s name.

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6 Programming and testing

6.6.4. Deleting a payload

6.6.4. Deleting a payload

Deleting a payload

Step

1.

2.

3.

4.

5.

Action

In the ABB menu, tap Jogging.

Tap Payload to display the list of available payloads.

Tap and hold the payload you want to delete.

A menu appears.

Tap Delete.

A confirmation dialog box appears.

In the dialog box, tap Yes to delete the payload, No to keep the payload.

CAUTION!

A deleted tool, work object or payload cannot be recovered, and all related data will be lost.

If the tool, work object or payload is referenced by any program, those programs cannot run without changes.

If you delete a tool you cannot continue the program from the current position.

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6 Programming and testing

6.7.1. Handling of programs

6.7 Programming

6.7.1. Handling of programs

Overview

This section details how to perform normal handling of existing robot programs. It details how to:

• create a new program

• load an existing program

• save a program

• rename a program

• delete a program

Each task must contain one program, no more, no less.

How to create a new program when no program is available is detailed in section

Creating a new program on page 165

.

About program files

When saving a program to the controller hard disk, it is by default saved to the directory

HOME in the system’s folder. The program is saved as a folder, named as the program, containing the actual program file, of type pgf.

When loading a program you open the program folder and select the pgf file.

When renaming a program you rename the program folder and the program file.

When saving a loaded program which is already saved to the hard disk, you must not open the existing program folder. Instead, you should save the program folder again and overwrite the old version, or rename the program.

Creating a new program

This section describes how to create a new program.

Step

1.

2.

3.

4.

5.

Action

On the ABB menu, tap Program Editor.

Tap Tasks and Programs.

Tap File, then New Program.

If there was already a program loaded, a warning dialog appears.

• Tap Save to save the loaded program.

• Tap Don’t save to close loaded program without saving it, i.e. delete from program memory.

• Tap Cancel to leave the program loaded.

Use the soft keyboard to name the new program. Then tap OK.

Tap Back to return to the editor view or Show modules to add existing modules to the new program. Continue by adding instructions, routines, or modules.

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6 Programming and testing

6.7.1. Handling of programs

Continued

Loading an existing program

This section describes how to load an existing program.

Step

1.

2.

3.

4.

Action

On the ABB menu, tap Program Editor.

Tap Tasks and Programs.

Tap File, then Load Program.

If there was already a program loaded, a warning dialog appears.

• Tap Save to save the loaded program.

• Tap Don’t save to close loaded program without saving it, i.e. delete from program memory.

• Tap Cancel to leave the program loaded.

Use the file searching tool to locate the program file to be loaded (file type pgf).

Then tap OK.

The program is loaded and the program code is displayed.

en0400000699

Saving a program

This section describes how to save a loaded program to the controller’s hard disk.

A loaded program is automatically saved in the program memory, but saving to the controller hard disk is an extra precaution.

Step

1.

2.

Action

On the ABB menu, tap Program Editor.

Tap Tasks and Programs.

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6.7.1. Handling of programs

Continued

Step

3.

4.

Action

Tap File and select Save Program As....

Use the suggested program name or tap ... to open the soft keyboard and enter a new name. Then tap OK.

Renaming a loaded program

This section describes how to rename a loaded program.

Step

1.

2.

3.

4.

Action

On the ABB menu, tap Program Editor.

Tap Tasks and Programs.

Tap File and select Rename Program.

A soft keyboard is displayed.

Use the soft keyboard to enter the new name of the program. Then tap OK.

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6 Programming and testing

6.7.2. Handling of modules

6.7.2. Handling of modules

Overview

This section details how to handle program modules. i.e.:

• create a new module

• load an existing module

• save a module

• rename a module

• delete a module

Creating a new module

This section describes how to create a new module.

Step

1.

2.

3.

Action

On the ABB menu, tap Program Editor.

Tap Modules.

Tap File, then tap New Module.

168

4.

5.

en0400000688

Tap ABC... and use the soft keyboard to enter the new module’s name. Then tap

OK to close the soft keyboard.

Select which type of module to be created:

• Program

• System

Then tap OK.

The differences between module types are described in section

The structure of a RAPID application on page 134

.

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Loading an existing module

This section describes how to load an existing module.

Step

1.

2.

3.

Action

On the ABB menu, tap Program Editor.

Tap Modules.

Tap File, then Load Module.

6 Programming and testing

6.7.2. Handling of modules

Continued

4.

en0400000689

Locate the module to be loaded. See section

FlexPendant Explorer on page 75

.

Tap OK to load the selected module.

The module is loaded.

Saving a module

This section describes how to save a module.

Step

1.

2.

Action

On the ABB menu, tap Program Editor.

Tap Modules and tap to select the module you want to load.

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6 Programming and testing

6.7.2. Handling of modules

Continued

Step

3.

Action

Tap File, then Save Module As...

4.

5.

en0400000690

Tap on the suggested file name and use the soft keyboard to enter the module’s name. Then tap OK.

Use the file searching tool to locate where you want to save the module. See

section

FlexPendant Explorer on page 75

. The default location is on the controller

disk.

The tap OK.

The module is saved.

Renaming a module

This section describes how to rename a module.

Step

1.

2.

3.

4.

Action

On the ABB menu, tap Program Editor.

Tap Modules.

Tap File, then Rename Module...

The soft keyboard is displayed.

Use the soft keyboard to enter the module’s name. Then tap OK.

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6.7.2. Handling of modules

Continued

Deleting a module

This section describes how to delete a module from memory. If the module has been saved to disk, it will not be erased from the disk..

Step

1.

2.

3.

4.

Action

On the ABB menu, tap Program Editor.

Tap Modules and tap to select the module you want to delete.

Tap File, then Delete Module...

A dialog box is displayed.

Tap OK to delete the module without saving it.

If you want to save the module first, tap Cancel and save the module first.

How to save the module is detailed in section

Saving a module on page 169

.

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6 Programming and testing

6.7.3. Handling of routines

6.7.3. Handling of routines

Overview

This section details how to handle program routines. i.e.:

• create a new routine

• create a copy of a routine

• change the declaration of a routine

• delete a routine

Creating a new routine

This section details how to create a new routine, set the declaration, and add it to a module.

Step

1.

2.

3.

Action

On the ABB menu, tap Program Editor.

Tap Routines.

Tap File, then New Routine.

A new routine is created and displayed with default declaration values.

172

4.

5.

6.

en0400000692

Tap ABC... and use the soft keyboard to enter the new routines’ name. Then tap

OK.

Select the type of routine:

• Procedure: used for a normal routine without return value

• Function: used for a normal routine with return value

• Trap: used for an interrupt routine

Do you need to use any parameters?

If YES; tap ... and proceed as detailed in section

Defining parameters in routine on page 173

.

If NO; proceed to the next step.

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6.7.3. Handling of routines

Continued

Step

7.

8.

9.

Action

Select module to add the routine to.

Tap the checkbox to select Local declaration if the routine should be local.

A local routine can only be used in the selected module.

Tap OK.

Defining parameters in routine

This section describes how to define parameters in a routine.

Step

1.

Action

In the routine declaration, tap ... to define parameters.

A list of defined parameters is displayed.

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173

6 Programming and testing

6.7.3. Handling of routines

Continued

Step

2.

Action

If no parameters are shown, tap Add to add a new parameter.

• Add optional parameter adds a parameter that is optional

• Add optional mutual parameter adds a parameter that is mutually optional with another parameter

Read more about routine parameters in the RAPID reference manuals.

3.

en0400000695

Use the soft keyboard to enter the name of the new parameter and then tap OK.

The new parameter is displayed in the list.

174

4.

en0400000696

Tap to select a parameter. To edit values, tap the value.

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6 Programming and testing

6.7.3. Handling of routines

Continued

Step

5.

Action

Tap OK to return to the routine declaration.

Creating a copy of a routine

This section describes how to create a copy of a routine.

Step

1.

2.

3.

4.

5.

Action

On the ABB menu, tap Program Editor.

Tap Routines.

Highlight the routine by tapping it.

Tap File, then Create copy.

The new routine is displayed. The name of the new routine is set to the same as the original with the suffix Copy.

Make any changes in the declarations for the new routine copy. Then tap OK.

How to make all declarations is detailed in section

Creating a new routine on page

172

.

Changing the declaration of a routine

This section describes how to change the declaration of a routine.

Step

1.

2.

3.

4.

5.

Action

On the ABB menu, tap Program Editor.

Tap Routines.

Highlight the routine by tapping it.

Tap File, then Change Declaration

Change any declaration values for the routine. Then tap OK.

Declaration settings are described in section

Creating a new routine on page 172

.

Deleting a routine

This section describes how to delete a routine from memory.

Step

1.

2.

3.

4.

5.

Action

On the ABB menu, tap Program Editor.

Tap Routines.

Highlight the routine by tapping it.

Tap File, then Delete routine...

A dialog box is displayed.

Tap:

• OK to delete the routine without saving any changes made to it.

• Cancel to revert without deleting the routine.

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6 Programming and testing

6.7.4. Handling of instructions

6.7.4. Handling of instructions

Instructions

A RAPID program consists of instructions. An instruction can, for example, move the robot, set an I/O signal, or write a message to the operator.

A large number of instructions are available, and these are listed in

RAPID reference manual

- Instructions

. The basic procedure for adding instructions are, however, identical.

Undo and redo

When editing programs in the Program editor, you can undo and redo up to three steps. This function is available in the Edit menu.

Adding instructions

This section describes how to add instructions.

Step

1.

2.

3.

Action

On the ABB menu, tap Program Editor.

Tap to highlight the instruction under which you want to add a new instruction.

Tap Add instruction.

A category of instructions is displayed.

176 en0400000697

A large number of instructions, divided into several categories, are available. The default category is Common, where the most common instructions are listed.

You can create three personalized lists using the system parameters of the type

Most Common Instruction in the topic Man-machine Communication. The system parameters are described in

Technical reference manual - System parameters

.

Continues on next page

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6 Programming and testing

6.7.4. Handling of instructions

Continued

Step

4.

5.

Action

Tap Common to display a list of the available categories.

You can also tap Previous/Next at the bottom of the list of instructions to move to the next/previous category.

Tap the instruction you want to add.

The instruction is added to the code.

Editing instruction arguments

This section describes how to edit instruction arguments.

Step

1.

Action

Tap the instruction to edit.

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6 Programming and testing

6.7.4. Handling of instructions

Continued

Step

2.

Action

Tap Edit.

3.

en0400000701

Tap Change Selected.

Depending on the type of instruction, the arguments have different data types.

Use the soft keyboard to change string values or proceed to the next steps for other data types or multiple argument instructions.

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Step

4.

Action

Tap the argument to be changed.

A number of options are displayed.

6 Programming and testing

6.7.4. Handling of instructions

Continued

5.

en0400000703

Tap an existing data instance to select and then tap OK to complete, or tap Insert

Expression... See more about expressions in section

Editing instruction expressions and declarations on page 188

.

To edit a particular data instance, see

Editing instruction expressions and declarations on page 188

.

TIP!

Tapping twice on an instruction will automatically launch the Change selected option.

Tapping twice on an instruction argument will automatically launch the argument editor.

Copying and pasting instructions or arguments

This section describes how to paste instructions or arguments.

Step

1.

2.

3.

Action

Tap to select the argument or instruction you want to copy and then tap Edit.

Tap Copy.

Place the cursor on the instruction above where you want to paste the instruction or argument, or tap on the argument or instruction you want to change and tap

Paste.

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6 Programming and testing

6.7.4. Handling of instructions

Continued

Cutting an instruction

This section describes how to cut an instruction.

Step

1.

2.

Action

Tap to select the instruction you want to cut and then tap Edit.

Tap Cut.

Changing motion mode for a move instruction

This section describes how to change the motion mode for a move instruction.

Step

1.

2.

Action

Tap to select the move instruction you want to change and then tap Edit.

Tap Change to Joint or Change to Linear.

The change is performed.

Commenting instruction rows

Instruction rows can be commented, i.e. skipped in the program execution. The comment/ uncomment command is found under the Edit menu in the Program editor.

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6 Programming and testing

6.7.5. Example: Add movement instructions

6.7.5. Example: Add movement instructions

Overview

In this example you will create a simple program that makes the robot move in a square. You need four movement instructions to complete this program.

A

B en0400000801

C

A

B

C

First point

Robot movement Speed data v50 = speed 50mm/s

Zone z50 = (50mm)

Add movement instructions

This section details how to add movement instructions.

Step

1.

2.

3.

4.

5.

6.

Action

Jog the robot to the first point.

In the program editor, tap Add Instruction.

Tap MoveL to insert a

MoveL

instruction.

Repeat for the next three positions of the square.

Tap on z50 in the last instruction. Tap Edit and then Change selected.

Tap Fine to make the square end in a stop point.

Tap OK.

Info

Tip: Use only left-right/updown joystick movements to jog in a square.

Result

Your program code should look like this:

Proc main()

MoveL *, v50, z50, tool0;

MoveL *, v50, z50, tool0;

MoveL *, v50, z50, tool0;

MoveL *, v50, fine, tool0;

End Proc;

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6 Programming and testing

6.8.1. Mirroring a program, module, or routine

6.8 Advanced programming

6.8.1. Mirroring a program, module, or routine

Mirroring

Mirroring creates a copy of a program, module, or routine with all positions mirrored in a specific mirror plane. In general, all data used in the original will be mirrored. Mirroring data only affects the initialization value, i.e. any current value will be ignored.

The mirror function can be applied to any program, module, or routine.

Mirroring a routine

This section describes how to mirror a routine.

Step

1.

2.

3.

4.

5.

6.

Action

In the ABB menu, tap Program Editor.

Tap Edit and tap Mirror.

To define the mirror.

• Tap the Module menu to select in which module the routine to mirror is used.

• Tap the Routine menu to select which routine you want to mirror.

• Tap ... to open the soft keyboard and enter the name for the new routine.

If you want to define the type of mirror then tap Advanced options, otherwise proceed to the next step.

To define the type of mirror:

• Deselect the Base Mirror checkbox.

• Tap ... to the right of Work object to select the work object frame to which all positions which are to be mirrored are related to.

• Tap ... to the right of Mirror frame to select the mirror plane to which all positions will be mirrored.

• Tap the Axis to mirror menu to specify the mirroring orientation, x or y.

• Tap OK to save the advanced options.

Tap OK.

A dialogue box is displayed.

Tap Yes to apply the selected mirror to the routine, or tap No to cancel.

Mirroring a module or program

This section describes how to mirror a module or program.

Step

1.

2.

3.

Action

In the ABB menu, tap Program Editor.

Tap Edit and tap Mirror.

To define the mirror.

• Tap the Module menu to select module to mirror.

• Tap ... to open the soft keyboard and enter the name for the new module or program.

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6 Programming and testing

6.8.1. Mirroring a program, module, or routine

Continued

Step

4.

5.

6.

Action

If you want to define the type of mirror then tap Advanced options, otherwise proceed to the next step.

To define the type of mirror:

• Deselect the Base Mirror checkbox.

• Tap ... to the right of Work object to select the work object frame to which all positions which are to be mirrored are related to.

• Tap ... to the right of Mirror frame to select the mirror plane to which all positions will be mirrored.

• Tap the Axis to mirror menu to specify the mirroring orientation, x or y.

• Tap OK to save the advanced options.

Tap OK.

A dialogue box is displayed.

Tap Yes to apply the selected mirror to the module, or tap No to cancel.

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6 Programming and testing

6.8.2. Modifying positions

6.8.2. Modifying positions

Overview modifying positions

Positions are instances of the data type robtarget or jointtarget. See RAPID reference manual

- Functions and data types.

The positions can be modified either using the function HotEdit, where you enter the new values using a soft keyboard, or using the Modify positions function in the Program editor where you step and jog the robot to the new position.

HotEdit is described in section

HotEdit on page 73

.

Note that jointtargets can only be modified using the Modify positions method in the Program editor, i.e. not with HotEdit.

CAUTION!

Changing programmed positions may significantly alter the robot’s movement pattern.

Always make sure any changes are safe for both equipment and personnel.

Overview modifying positions in the Program editor

When modifying positions by jogging the robot to the new position you can either single-step through the program to the position(s) you want to modify, or jog directly to the new position and change the corresponding position argument of the instruction.

The recommendation is to step to through the program to the position, but if you know your robot program well and the new position is known, it is faster to use the jogging method.

Note! Do not use this method to change orientation values.

To modify positions using the Program editor, the system must be in manual mode.

Modifying positions

This procedure describes how to modify positions, either by single-stepping to the positions or jogging.

Step

1.

2.

3.

4.

5.

6.

7.

Action Info

On the ABB menu, tap Program Editor.

Stop the program, if running.

Do you want to single-step to the position or jog?

If single-stepping, step through the program to the position you want to change. Make sure the correct argument is selected.

If jogging, use the Jogging view to make sure that the same work object and tool that are used in the instruction are selected.

Jog to the new position.

When using the jogging method, tap to select the position argument you want to change.

Tap Modify Position.

A confirmation dialog appears.

Tap Modify to use the new position, Cancel to keep the original.

When single-stepping, if the instruction or procedure call has more than one position argument, continue to step to reach each argument.

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6.8.2. Modifying positions

Continued

Step

8.

9.

Action

Repeat step 3 through 7 for each position argument you want to change.

Tap Close to close the Program Editor.

Info

Limitations

The Modify Position button in the Program editor is disabled until you select a position argument.

The maximum movement or change in orientation, may be restricted by the system parameters (topic Controller, type ModPos Settings) in the system design. Please read your cell or plant documentation for details.

If the system parameters are setup to use absolute limits for position changes, then the original positions can only be restored or changed using the baseline menu in HotEdit.

If a named position is changed, all other instructions using that position will be affected.

Related information

HotEdit on page 73

.

RAPID reference manual - Functions and data types.

Technical reference manual - System parameters.

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6 Programming and testing

6.8.3. Moving the robot to a programmed position

6.8.3. Moving the robot to a programmed position

Positions

A robot program usually contain programmed positions. The robot can move automatically to a programmed position using a function in the Jogging menu.

The robot will move at 250 mm/s.

DANGER!

When moving the robot automatically, the robot arm may move without warning. Make sure no personnel are in safeguarded space and that no objects are in the way between the current position and the programmed position.

Moving the robot to a programmed position

This procedure describes how to move a robot automatically to a programmed position.

Step

1.

2.

3.

4.

Action Info

On the ABB menu, tap Jogging.

Make sure the correct mechanical unit is selected and then tap Go To....

Tap to select a programmed position.

If you have many programmed positions you can use a filter to narrow down the visible positions.

See section

Filtering data on page 101

.

Press and hold the enabling device and then tap and hold the Go To button.

The robot now moves directly from the current position to the programmed position. Make sure no objects are in the way.

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6 Programming and testing

6.8.4. Aligning tools

6.8.4. Aligning tools

Overview

A tool can be aligned with another coordinate system.

When aligning a tool, the tool’s z axis is aligned to the selected coordinate system’s nearest axis. Therefore it is recommended to first jog the tool so it is close to the desired coordinates.

Note that the tool’s data is not changed!

Aligning mechanical units

This procedure describes how to align tools.

Step

1.

2.

Action

On the ABB menu, tap Jogging.

Make sure that the right tool is active and then tap Align....

3.

4.

5.

en0500001548

Select a coordinate system to align the the selected tool to.

Press and hold the enabling device and then tap and hold Start Align to start aligning the tool.

Tap Close when completed.

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6 Programming and testing

6.8.5. Editing instruction expressions and declarations

6.8.5. Editing instruction expressions and declarations

Expressions

An expression specifies the evaluation of a value. It can be used, for example:

• as a condition in an IF instruction

• as an argument in an instruction

• as an argument in a function call

Read more in RAPID reference manual - RAPID overview and RAPID reference manual -

Instructions.

Inserting expressions

This procedure describes how to insert and edit expressions in instructions.

Step

1.

2.

3.

Action

In the Program Editor, tap to select the instruciton you want to edit and then tap

Edit.

Tap Change selected and tap to select the argument to change.

Tap Insert expression.

188

4.

en0400000704

Edit the length of the expression by tapping the keys to the right:

• Arrows: step backward and forward in the expression.

• + to add expression. Tap the new expression to define it.

• - to delete expression.

• () to set a parenthesis around the highlighted expression.

• (o) to delete a parenthesis.

Continues on next page

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6 Programming and testing

6.8.5. Editing instruction expressions and declarations

Continued

Step

5.

6.

Action

Tap:

• New to create a new data declaration, i.e. adding a data declaration not previously used. This is detailed in section

Creating new data declarations on page 189

.

• View to change views or change data type. This is detailed in section

Changing data type on page 190

.

• ABC displays the soft keyboard.

Tap OK to save the expression.

Declarations and data types

When editing an expression new data can be declared with the button New. More information about data declarations and how to edit them can be found in section

Editing data instances on page 139

.

Creating new data declarations

This procedure describes how to create a new data declaration in an instruction expression.

Step

1.

Action

In the Insert Expression view, tap New.

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6 Programming and testing

6.8.5. Editing instruction expressions and declarations

Continued

Step

2.

3.

Action

Tap and enter desired values:

• Initial value to set the initial value.

• ... to display the soft keyboard and change the data type’s name.

•

Scope

•

Storage type

•

Module

•

Routine

• Dimension to set the size of an array if the data type should be an array.

• If a value has been chosen for Dimension, tap ... to set array size, see

What is a data array? on page 312

After making all selections, tap OK.

A dialog box is displayed, prompting you to allow resetting of the program pointer and applying all changes:

• Tap Yes to proceed.

• Tap No to return to the data type view without resetting of the program pointer or applying changes.

Changing data type

This section describes how to change data type.

Step

1.

Action

In the Insert Expression view, tap View and then Change data type, the following screen is displayed:

190

2.

en0400000706

Tap to select the required data type and tap OK.

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6 Programming and testing

6.8.6. Hiding declarations in program code

6.8.6. Hiding declarations in program code

Declarations

Program declarations can be hidden to make the program code easier to read.

Hiding declarations

This section describes how to hide or show declarations.

Step

1.

2.

Action

In the ABB menu, tap Program Editor to view a program.

Tap Hide Declarations to hide declarations.

Tap Show Declarations to show declarations.

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6 Programming and testing

6.8.7. Deleting programs from memory

6.8.7. Deleting programs from memory

Overview

Deleting a program in a task does not erase the program from the controller hard disk but only from the program memory.

When you switch programs, the previously used program is deleted from the program memory, but not removed from the hard disk if it was saved there.

How to save your work is detailed in section

Handling of programs on page 165

.

The different memories are described in section

What is “the memory”? on page 248

.

Deleting programs from memory

This section details how to delete programs from the program memory.

Step

1.

2.

3.

Action

On the ABB menu tap Program Editor.

Tap Tasks and Programs.

Tap File.

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6 Programming and testing

6.8.7. Deleting programs from memory

Continued

Step

4.

Action

Tap Delete Program....

WARNING! Recent program changes will not be saved.

5.

en0400000853

Tap OK.

If you don’t want to lose information about program changes then use Save

Program before deleting the program. How to save your work is described in section

Handling of programs on page 165

.

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6 Programming and testing

6.8.8. Deleting programs from hard disk

6.8.8. Deleting programs from hard disk

Overview

Programs are deleted via FlexPendant Explorer or an FTP client. When deleting programs from the controller hard disk, the currently loaded program in the program memory is not affected.

The different memories are described in section

What is “the memory”? on page 248

.

Deleting programs with FlexPendant Explorer

Programs can be deleted using FlexPendant Explorer on the ABB menu. See section

FlexPendant Explorer on page 75

.

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6 Programming and testing

6.8.9. Activating mechanical units

6.8.9. Activating mechanical units

Overview

A mechanical unit can be active or deactive. Only active units are run when executing a program. Deactivated units will not run. This may be useful when programming or testing a program.

A robot cannot be deactivated.

The Activate function does not affect jogging. To select mechanical unit for jogging, use the

Mechanical unit property in the Jogging menu.

Activating mechanical units

This procedure describes how to activate a mechanical unit.

Step

1.

2.

Action Info

On the ABB menu, tap Jogging.

Make sure that the right mechanical unit is selected, then tap Activate....

To deactivate an active mechanical unit, tap

Deactivate.

A robot cannot be deactivated.

Related information

Selecting mechanical unit on page 108

.

Mechanical units can be active or deactive at startup depending on the system setup, see

Technical reference manual - System parameters, topic Motion.

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6 Programming and testing

6.9.1. How to use the hold-to-run function

6.9 Testing

6.9.1. How to use the hold-to-run function

When to use the hold-to-run function

The hold-to-run function is used to run or step programs in manual full speed mode, in combination with the enabling device.

In systems with hold-to-run buttons on the back of the FlexPendant, one of these buttons are used. In systems without hold-to-run buttons, use the Start, Forward, or Backward buttons instead (press and hold). The hold-to-run function is the same.

Operational mode Function

Manual reduced speed mode Normally, hold-to-run has no effect in the manual reduced speed mode.

However, it is possible to activate for manual reduced speed mode by changing a system parameter.

Manual full speed mode Pressing hold-to-run AND pressing the enabling device enables running a program. It may be run continuously or step-by-step.

Releasing hold-to-run in this mode immediately stops manipulator movement as well as program execution. When pressing it again, execution is resumed from that position.

Automatic mode Hold-to-run is not used in automatic mode.

How to use the hold-to-run function

This instruction details how use the hold-to-run function in manual full speed mode.

Step

1.

2.

3.

4.

Action

Press the enabling device on the FlexPendant.

In a system with hold-to-run buttons, choose execution mode by pressing either:

• Start (continuous program execution)

• Forward (step-by step program execution forwards)

• Backward (step-by step program execution backwards)

Then wait for the hold-to-run alert box and press the hold-to-run button.

You can also select step mode, see section

Stepping instruction by instruction on page 205

.

In a system without hold-to-run buttons, choose execution mode by pressing and holding either:

• Start (continuous program execution)

• Forward (step-by step program execution forwards)

• Backward (step-by step program execution backwards)

If Start was pressed, then the program execution continues as long as the holdto-run or Start button is pressed.

If Forward or Backward was pressed, the program is executed step-by-step by alternately releasing and pressing the hold-to-run or the Forward/Backward button.

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6 Programming and testing

6.9.1. How to use the hold-to-run function

Continued

Step

5.

6.

7.

Action

If the hold-to-run button is released, program execution stops.

If the hold-to-run button is pressed again after being released, program execution is resumed from the position in which it was released.

It is possible to change execution mode when the hold-to-run button is released and then continue the program execution with the new execution mode, by just activating the hold-to-run button again.

If the enabling device is released, intentionally or by accident, the complete procedure must be repeated to enable running.

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6 Programming and testing

6.9.2. Running the program from a specific instruction

6.9.2. Running the program from a specific instruction

Running the program from a specific instruction

This section details how to run the program from a specific instruction.

Step

1.

2.

Action

On the ABB menu Tap Program Editor.

Tap Debug.

198 en0400000868

Tap on the program step where you want to start, then tap Debug and select

Move PP to Cur.

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6 Programming and testing

6.9.2. Running the program from a specific instruction

Continued

Step

3.

Action

4.

xx

Make sure that no personnel are in the robot working area.

WARNING! Before running the robot, observe the safety information in section

DANGER - Moving manipulators are potentially lethal! on page 18

.

Press the Start button on the FlexPendant hardware button set (see E in illustration below).

en0300000587

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6 Programming and testing

6.9.3. Running a specific routine

6.9.3. Running a specific routine

Overview

To run a specific routine you must have the module with the routine loaded. How to run service routines is described in section

Running a service routine on page 209

.

Running a specific routine

This procedure describes how to run a specific routine in manual mode.

Step

1.

2.

3.

Action

On the ABB menu, tap Program Editor.

Tap Debug and then Move PP to routine to place the program pointer at the start of the routine.

Press the Start button on the FlexPendant.

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6 Programming and testing

6.9.4. Quickset menu, Run Mode

6.9.4. Quickset menu, Run Mode

Run mode

By setting run mode you define if the program execution should run once and then stop, or run continuously.

Under the Run mode menu, you can also select which tasks should be active or deactivated if you have the Multitasking option installed. Select task is also available under the Quickset

Step mode menu.

Select run mode

This section describes how to select run mode using the Quickset menu.

Step

1.

Action

If you want to view/change any Run mode functionality, tap the Run Mode button.

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The following buttons are displayed:

• Single cycle running

• Continuous running

The Show tasks button opens the list with available tasks.

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6 Programming and testing

6.9.4. Quickset menu, Run Mode

Continued

Step

2.

Action

If you want to view/change which tasks that are active, tap the Show Tasks button.

To select tasks you must be in manual mode.

en0400000992

The following is displayed:

• A list of all available tasks. Tap to activate or deactivate tasks.

• Hide tasks will hide the task list.

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6 Programming and testing

6.9.5. Quickset menu, Step Mode

6.9.5. Quickset menu, Step Mode

Step mode

By setting step mode you define how the step-by-step program execution should function.

Under the Step mode menu, you can also select which tasks should be active or deactivated if you have the Multitasking option installed. Select task is also available under the Quickset

Run mode menu.

Select step mode

This section describes how to select step mode using the Quickset menu.

Step

1.

Action

If you want to view/change any Step mode functionality, tap the Step Mode button.

3HAC 16590-1 Revision: B en0300000543

After tapping Step Mode, the following buttons are displayed:

• Step into. Steps into called routines and executes them step-by-step.

• Step out. Executes the remains of the current routine and then stops at the next instruction in the routine from which the current routine was called.

Not possible to use in the Main routine.

• Step over. Called routines are executed in one single step.

• Next move instruction. Steps to the next move instruction. Stops before and after movement instructions to allow e.g. modifying positions.

Show tasks opens the list of available tasks.

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6 Programming and testing

6.9.5. Quickset menu, Step Mode

Continued

Step

2.

Action

If you want to view/change which tasks that are active, tap the Show Tasks button.

To select tasks you must be in manual mode.

en0400000993

The following is displayed:

• A: A list of all available tasks. Tap to activate or deactivate tasks.

• B: Hide tasks will hide the task list.

Related information

Modifying positions on page 184

.

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6 Programming and testing

6.9.6. Stepping instruction by instruction

6.9.6. Stepping instruction by instruction

Overview

In all operating modes the program may be executed step by step forwards or backwards.

Stepping backwards is limited, see

RAPID overview

for more details.

Select step mode

This section details how to select step mode. Stepping can be done in three ways; step in, step over, and motion step.

Step

1.

Action

Select step mode using the Quickset menu.

Info

Described in

Quickset menu, Step

Mode on page 203

.

Stepping

This section details how to step forwards and backwards.

If you want to step...

forward backward

then press...

Forward button on FlexPendant

Backward button on FlexPendant

Limitations of backward execution

There are some restrictions for the backward execution:

•

When stepping backwards through a

MoveC

instruction, the execution does not stop in the circular point.

• It is not possible to step backwards out of a

IF

,

FOR

,

WHILE

and

TEST

statement.

•

It is not possible to step backwards out of a routine when reaching the beginning of the routine.

• There are instructions affecting the motion that cannot be executed backwards (e.g.

ActUnit

,

ConfL

and

PDispOn

). If attempting to execute these backwards, an alert box will inform you that this is not possible.

Backward execution behavior

When stepping forward though the program code, a program pointer indicates the next instruction to execute and a motion pointer indicates the move instruction that the robot is performing.

When stepping backward though the program code, the program pointer indicates the instruction above the motion pointer. When the program pointer indicates one move instruction and the motion pointer indicates another, the next backward movement will move to the target indicated by the program pointer, using the type of movement and speed indicated by the motion pointer.

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6 Programming and testing

6.9.6. Stepping instruction by instruction

Continued

Example of backward execution

This example illustrates the behavior when stepping backwards through move instructions.

The program pointer and motion pointer helps you keep track of where the RAPID execution is and where the robot is.

MoveL

,

MoveJ

, and

MoveC

are move instructions in RAPID, see RAPID reference manual -

Instructions.

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A

B

C

Program pointer

Motion pointer

Highlighting of the robtarget that the robot is moving towards, or already has reached.

When...

then...

stepping forward until the robot is in p5 the motion pointer will indicate p5 and the program pointer will indicate the next move instruction (

MoveL p6

).

pressing the

Backward button once pressing the

Backward button again pressing the

Backward button again the robot will not move but the program pointer will move to the previous instruction (

MoveC p3, p4

). This indicates that this is the instruction that will be executed the next time Backward is pressed.

the robot will move to p4 linearly with the speed v300.

The target for this movement (p4) is taken from the

MoveC

instruction.

The type of movement (linear) and the speed are taken from the instruction below (

MoveL p5

).

The motion pointer will indicate p4 and the program pointer will move up to

MoveL p2

.

the robot will move circularly, via p3, to p2 with the speed v100.

The target p2 is taken from the instruction

MoveL p2

. The type of movement (circular), the circular point (p3) and the speed are taken from the

MoveC

instruction.

The motion pointer will indicate p2 and the program pointer will move up to

MoveL p1

.

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6 Programming and testing

6.9.6. Stepping instruction by instruction

Continued

When...

then...

pressing the

Backward button again the robot will move linearly to p1 with the speed v200.

The motion pointer will indicate p1 and the program pointer will move up to

MoveJ p0

.

pressing the Forward button once the robot will not move but the program pointer will move to the next instruction (

MoveL p2

). pressing the Forward button again the robot will move to p2 with the speed v200.

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6 Programming and testing

6.9.7. Quickset menu, Speed

6.9.7. Quickset menu, Speed

Speed button

The speed settings apply to the current operating mode. However, if you decrease the speed in automatic mode, the setting also applies to manual mode if you change mode.

Step

1.

Action

If you want to view/change any Speed functionality, tap the Speed button.

208 en0300000470

The following buttons are displayed (from top left):

• Actual running speed (in relation to max)

• Decrease running speed in steps of 1%

• Increase running speed in steps of 1%

• Decrease running speed in steps of 5%

• Increase running speed in steps of 5%

• Run at quarter speed (25%)

• Run at half speed (50%)

• Run at full speed (100%)

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6 Programming and testing

6.10.1. Running a service routine

6.10 Service routines

6.10.1. Running a service routine

Service routines

Service routines are routines for performing a number of common services. The service routines available depend on your system setup and available options. Please refer to your plant or cell documentation for more information.

Note that once a service routine has started running, aborting might not resume the system to previous state since the routine may have moved the robot arm.

Running a service routine

This section describes how to run a service routine in manual mode.

Step

1.

2.

Action

On the ABB menu tap Program Editor.

Tap Debug.

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6 Programming and testing

6.10.1. Running a service routine

Continued

Step

3.

Action

Tap Call Service Routine to list the service routines. Tap the routine you want to run and tap Go to.

4.

en0400000885

If the routine was loaded properly, press Start on the FlexPendant.

The routine is now started and run. Follow any instructions on the screen.

Related information

Battery shutdown service routine on page 211

.

LoadIdentify, load identifiction service routine on page 214

.

Service Information System, ServiceInfo service routine on page 213

.

Calibration Pendulum, CalPendulum service routine on page 212

.

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6 Programming and testing

6.10.2. Battery shutdown service routine

6.10.2. Battery shutdown service routine

Bat_shutdown

It is possible to shutdown the battery backup of the Serial Measurement Board to save battery power during transportation or storage. The function is reset when the system is powered on again. The revolution counters will be lost and needs an update but the calibration values will remain.

Related information

How to start a service routine is described in

Running a service routine on page 209

.

The Serial Measurement Board is described in

Serial Measurement Board memory on page

280

.

How to update the revolution counters is described in

Updating revolution counters on page

274

.

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6 Programming and testing

6.10.3. Calibration Pendulum, CalPendulum service routine

6.10.3. Calibration Pendulum, CalPendulum service routine

CalPendulum

CalPendulum is a service routine used with Calibration Pendulum, the standard method for calibration of ABB robots. This is the most accurate method for the standard type of calibration, and it is also the recommended method in order to achieve proper performance.

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the manual Calibration Pendulum instruction.

Related information

Running a service routine on page 209

.

Calibration Pendulum is described in full in the manual Calibration Pendulum instruction.

Specific information for each robot is described in the robot’s product manual.

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6 Programming and testing

6.10.4. Service Information System, ServiceInfo service routine

6.10.4. Service Information System, ServiceInfo service routine

ServiceInfo

ServiceInfo is a service routine based on Service Information System, SIS, a software function which simplifies maintenance of the robot system. It supervises the operating time and mode of the robot, and alerts the operator when a maintenance activity is scheduled.

Maintenance is scheduled by setting the system parameters of the type SIS parameters. How to work with system parameters is described in section

Configuring system parameters on page 270

. All system parameters are described in Technical reference manual - System

parameters. See also the product manual for the robot.

Supervised functions

The following counters are available:

• Calender time counter

•

Operation time counter

• Gearbox operation time counters

Counters are reset when maintenance has been performed.

The counter status is displayed after running the ServiceInfo routine for maintenance. Status

“OK” indicates that no service interval limit has been exceeded by that counter.

Related information

Running a service routine on page 209

.

Configuring system parameters on page 270

.

The system parameters for SIS are described in Technical reference manual - System

parameters, chapter Motion.

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6 Programming and testing

6.10.5. LoadIdentify, load identifiction service routine

6.10.5. LoadIdentify, load identifiction service routine

Overview

The service routine LoadIdentify is used to automatically calculate the data of loads mounted on the robot. You can also enter the data manually, but this requires information that may be difficult to calculate.

If you want to run load identification for the payload, make sure that the tool is correctly defined first, e.g. by running LoadIdentify for the tool.

To run LoadIdentify, there are a number of things to consider. These are described on the following pages. You can also find information on error handling and limitations in this chapter.

LoadIdentify

LoadIdentify can identify the tool load and the payload. The data that can be identified are mass, center of gravity, and moments of inertia. Together with the identified data a measurement accuracy, indicating how well the identification went, is also given.

en0500001535

A

B

C

Upper arm load

Tool load

Payload

The movements of axis 3 will only be performed if the mass is to be identified. This means that to identify the mass, the upper arm load must be known and correctly defined first.

Calibration angles

To perform the identification the robot moves the load after a specific pattern and calculates the data. The axes that move are 3, 5 and 6. At the identification position, the motion for axis

3 is approximately 3 degrees up and 3 degrees down and for axis 5 it is approximately 30 degrees up and 30 degrees down. For axis 6 the motion is performed around two configuration points.

The optimum value for the configuration angle is 90 degrees.

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6.10.5. LoadIdentify, load identifiction service routine

Continued

en0500001537

A

B

C

Configuration 2

Configuration angle

Configuration 1 (start position)

LoadIdentify with arm loads mounted

The best way to perform load identification is with a robot with no arm loads mounted. If this is not possible, good accuracy can still be achieved. Consider, for example, the robot in the figure below, which has arc welding equipment mounted on it.

en0500001536

A

B

C

D

Cable 1

Load 1

Cable 2

Load 2

If we want to use load identification to find the data of load 2, the most important thing to remember is to make sure that the upper arm load is correctly defined, in particular its mass and its center of gravity along the robot arm. The arm load includes everything that is mounted on the robot, except tool load and payload. In the figure above, cable 1, cable 2, and load 1 are included in the arm load.

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6 Programming and testing

6.10.5. LoadIdentify, load identifiction service routine

Continued

When performing the load identification, cable 2 should be disconnected since it will otherwise put an extra force on load 2. When identifying load 2 with such a force present, the result may differ considerably from the correct load. Ideally, cable 2 should be disconnected from load 2 and fastened on the upper arm. If this is not possible, the cable can also be disconnected at load 1 and fastened to the upper arm in such a way that the resulting force on load 2 in minimised.

Prerequisites for tool loads

Before running the LoadIdentify service routine for a tool load, make sure that:

• the tool is selected in the jogging menu

• the tool is correctly mounted

• axis 6 is close to horizontal and that axis 4 is not too far away from 0 degrees

• the upper arm load is known, if the mass is to be identified

• the axes 3, 5, and 6 are not close to their corresponding working range limits

• the speed is set to 100%

• the system is in manual mode.

Note that LoadIdentify cannot be used for tool0.

Prerequisites for payloads

Before running the LoadIdentify service routine for a payload, make sure that:

• the tool and payload are correctly mounted

• axis 6 is close to horizontal and that axis 4 is not too far away from 0 degrees

• the tool load is known (run LoadIdentify for the tool first)

• the upper arm load is known, if the mass is to be identified

• when using a moving TCP, the tool must be calibrated (TCP)

• when using a stationary TCP, the corresponding work object must be calibrated (user frame and object frame)

• the axes 3, 5, and 6 are not close to their corresponding working range limits

• the speed is set to 100%

• the system is in manual mode.

Running LoadIdentify

To start the load identification service routine you must have an active program in manual mode and the tool and payload that you want to identify must be defined and active in the jogging window.

Step

1.

2.

Action Info

Start LoadIdentify from the program editor. Press the enabling device and then the Start button on the

FlexPendant.

How to start service routines is described in

Running a service routine on page 209

.

Tap Tool or Payload.

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6 Programming and testing

6.10.5. LoadIdentify, load identifiction service routine

Continued

Step Action Info

3.

4.

5.

6.

7.

Tap OK to confirm that the correct tool and/or payload is active in the jogging menu and that the tool load/ payload is correctly mounted.

If it is not correct, release the enabling device and select the correct tool/ payload in the jogging menu. Then return to

LoadIdentify, press the enabling device, and press Start. Tap Retry and confirm that the new tool/ payload is correct.

See above.

When identifying tool loads, confirm that the tool is active.

When identifying payloads, confirm that the payload’s tool is active and calibrated.

When identifying payloads with stationary TCP, confirm that the correct work object is active and

(preferably) calibrated. If it is correct, tap OK to confirm.

Select identification method. If you select the method where the mass is assumed to be known, remember that the tool/payload that you use must have the correct mass defined. Tap OK to confirm.

Select configuration angle. The optimum is +90 or -90 degrees. If this is impossible, tap Other and set the angle. The minimum is plus or minus 30 degrees.

See above.

8.

9.

If the robot is not in a correct position for load identification, you will be asked to jog one or more axes roughly to a specified position. When you have done this tap OK to confirm.

If the robot is still not in a correct position for load identification, the robot will slowly move to the correct position. Press Move to start the movement.

The robot can go through the load identification movements slowly before performing the load identification. Tap Yes if you want a slow test and No to proceed to the identification.

This is useful for ensuring that the robot will not hit anything during the identification. However, this will take a lot longer time.

10.

The setup for load identification is now complete. To start the motion, switch to Automatic mode and

Motors On. Then tap Move to start the load identification movements.

11.

When the identification is finished, switch back to manual mode, press the enabling device and the

Start button. Tap OK to confirm.

12.

The result of the load identification is now presented on the FlexPendant. Tap Yes if you want to update the selected tool or payload with the identified parameters or No otherwise.

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6 Programming and testing

6.10.5. LoadIdentify, load identifiction service routine

Continued

Error handling

If the enabling device is released during the load identification (before the movements start), the routine can always be restarted by pressing the enabling device again and then pressing the Start button.

If an error should occur during the load identification movements, the routine must be restarted from the beginning. This is done automatically by pressing Start after confirming the error. To interrupt and leave the load identification procedure, tap Cancel Call Routine in the program editor’s debug menu.

Limitations for LoadIdentify

Only tool loads and payloads can be identified with LoadIdentify. Thus arm loads cannot be identified using this procedure.

If the load identification movements are interrupted by any kind of stop (program stop, emergency stop, etc.), the load identification must be restarted from the beginning. This is done automatically if you press Start after confirming the error.

If the robot is stopped on a path with program stop and load identification is performed at the stop point, the path will be cleared. This means that no regain movement will be performed to return the robot back to the path.

If the measurement accuracy is lower than 80%, the result of the load identification may have significant errors. In this case, a higher accuracy may be achieved by repeating the

LoadIdentify routine. If repeating the routine does not give a higher accuracy, then the torques measured in the identification are probably too small and the tool and/or payload data must be set manually. This is typically the case if the mass of the load is small (10% or less of the maximum load). It can also happen if the load has a particular symmetry property, for instance if the tool load is symmetrical around axis 6. However, even if the measurement accuracy is low some of the identified data may still be correct.

Load identification for suspended robots is only available for bending backward robots, e.g.

IRB 140.

Related information

It is also possible to include LoadIdentify in a program by using RAPID instructions. These are described in RAPID reference manual - Instructions and RAPID reference manual -

Functions and data types.

How to enter the data manually is described in

Editing the tool data on page 148

, and

Editing the payload data on page 162

.

The product manual for the robot contain information on how and where to mount the loads.

Load identification for positioners is done with the service routine ManLoadIdentify. This is described in the manual System settings for the positioner.

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7 Running in production

7.1. Starting programs

7 Running in production

7.1. Starting programs

Starting programs

This procedure details how to start a program for the first time or to continue running a program that has been stopped.

If your robot system has the multitasking option installed, also see

Using multitasking programs on page 222

.

Step

1.

2.

3.

4.

Action

Check that all necessary preparations are done to the robot and in the robot cell and that no obstacles exist within the robot’s working area.

Make sure no personnel are inside the robot cell.

Select operating mode on the control module.

Press the Motors on button on the control module to activate the robot.

Info/illustration

6.

7.

5.

Is a program loaded?

If yes, proceed to the next step.

If no, load a program.

Press the Start button on the FlexPendant to start the program.

Is the Return to path dialog box displayed?

If yes, return the robot to the path using a suitable method.

If no, proceed.

en0400000783

• A: Button for "Motors on"

How to load programs is described in section

Handling of programs on page 165

.

The button is shown in section

Hardware buttons on page 39

.

Returning the robot to the path is described in section

Returning the robot to the path on page

224

.

3HAC 16590-1 Revision: B

Continues on next page

219

7 Running in production

7.1. Starting programs

Continued

Continue running after the program is changed

You may always continue a program even if it has been changed.

In automatic mode, a warning dialog may appear to avoid restarting the program if the consequences are unknown.

If you...

then tap...

are sure the changes you have made are not in conflict with the robot’s current position and that the program can continue without danger to equipment or personnel

Yes are unsure of the consequences your changes might have and want to investigate further

No

Restart from the beginning

This procedure details how to restart a program from the beginning.

Step

1.

2.

3.

4.

Action

On the ABB menu, tap Program Editor.

Tap Debug.

Tap Move PP to Main.

Start the program by pressing the Start button on the FlexPendant.

Limitations

Only one program at a time may run, unless your system has the multitasking option. If so several programs may run simultaneously.

If the robot system encounters program code errors while the program is running, it will stop the program and the error is logged in the event log.

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7 Running in production

7.2. Stopping programs

7.2. Stopping programs

Stopping programs

If your robot system has the multitasking option installed, see

Using multitasking programs on page 222

.

Step

1.

2.

3.

Action

Check that the ongoing operation is in such a state that it can be interrupted.

Make sure it is safe to stop the program.

Press the Stop button on the FlexPendant hardware button set.

The button is shown in section

Hardware buttons on page 39

.

DANGER!

Do not use the Stop button in an emergency. Use the emergency stop button.

Stopping a program with the stop button does not mean that the robot will stop moving immediately.

Stopping execution when using hold-to-run or step-by-step execution

When using hold-to-run or step-by-step execution, execution can be stopped according to the following.

Mode

Operation with hold-to-run

Action

Release the hold-to-run button

Operation without hold-to-run Press the STOP button

Step-by-step mode The robot will stop after executing each instruction.

Execute the next instruction by pressing the Forward button again.

Info

The hold-to-run button is described in section

What is a FlexPendant? on page 38

.

The STOP button is described in section

What is a FlexPendant? on page 38

.

The STOP and Forward button are described in section

What is a

FlexPendant? on page 38

.

If you press the STOP button while executing a move instruction, the robot will stop without completing the move.

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7.3. Using multitasking programs

7.3. Using multitasking programs

Overview

In a multitasking system you may have one or several programs running parallel, for instance in a multimove cell with more than one robot where each robot has its own task and program.

For general information on program handling, see

Handling of programs on page 165

.

Multitasking is described in Application manual - Engineering tools.

TIP!

Need to know more about tasks and programs? These concepts are described in

The structure of a RAPID application on page 134

.

Manually set up tasks

Tasks need to be set up in order to run as planned. Normally, all tasks are set up on delivery.

Setting up tasks is done by defining system parameters of the type Controller. See section

Configuring system parameters on page 270

on how to configure system parameters, or

Technical reference manual - System parameters

for information about the parameters.

You need detailed information to set up tasks manually. Please read your plant or cell documentation for details.

How tasks are run

Tasks may be defined as Normal, Static, or Semistatic. Static and Semistatic tasks are automatically started as soon as a program is loaded into that task.

Normal tasks are started when you press the Start button of the FlexPendant, and stopped when you press the Stop button.

The concepts of Static, Semistatic and Normal are described in

Technical reference manual -

System parameters

.

Load, run, and stop multitasking programs

This section describes how to load, run, and stop multitasking programs.

Step

1.

2.

3.

4.

5.

Action

Make sure there is more than one task set up. This is done using system parameters, see section

Using multitasking programs on page 222

.

Load programs to respective task using the Program Editor, this is described in

section

Loading an existing program on page 166

.

If one or more task should be disabled, go to the Quickset menu to do this. See

section

Quickset menu, Run Mode on page 201

.

Deselecting tasks can only be done in manual mode. When switching to automatic mode, an alert box will appear warning that not all tasks are selected to run.

Start program execution by pressing the start button. All active tasks are started.

Stop program execution by pressing the stop button. All active tasks are stopped.

222

Continues on next page

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7 Running in production

7.3. Using multitasking programs

Continued

How to load a program to a task

This section describes how to load a program to a task in a multitasking system. It is assumed that the tasks have been configured.

Step

1.

2.

3.

4.

5.

6.

Action

On the ABBmenu, tap Program Editor.

Tap Tasks and Programs.

Tap the task into which you want to load a program.

On the File menu, tap Load Program....

If you want to open a program in another folder, locate and open that folder. See description in

FlexPendant Explorer on page 75

.

The file dialog box appears.

Tap the program you want to load followed by OK.

Tap Close to close the Program Editor.

Viewing multitasking programs

In the Production Window, there is one tab for each task. To switch between viewing the different tasks, tap on the tabs.

To edit several tasks in parallel, open one Program Editor for each task.

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7 Running in production

7.4. Returning the robot to the path

7.4. Returning the robot to the path

About paths and return regions

While a program runs, the robot or additional axis is considered to be on path which means that it follows the desired sequence of positions.

If you stop the program the robot is still on path, unless you change its position. It is then considered to be off path. However, if the robot is stopped by an emergency or safety stop it may be off path.

If the stopped robot is within the path return region you can start the program again, and the robot will return to the path and continue the program.

Note that there is no way to predict the exact return movement for the robot.

TIP!

The path return region is set with system parameters. This is described in the

Technical reference manual - System parameters

.

Returning to path

Step

1.

2.

3.

4.

Action

Make sure there are no obstacles blocking the way and that payloads or work objects are properly placed.

If necessary, put the system in automatic mode and press the Motors on button on the controller to activate the robot’s motors.

Press the Start button on the FlexPendant to continue the program from where it stopped.

One of two thing will happen:

• The robot or axis slowly returns to the path and the program continues.

• The return to path dialog is displayed.

If the return to path dialog is displayed, select the proper action.

Select action

If you...

then tap...

want to return to the path and continue the program want to return to the next target position and continue the program

Path

Position

don't want to return to the path and continue the program

Cancel

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7 Running in production

7.5.1. Present operating mode

7.5 Operating modes

7.5.1. Present operating mode

Overview

Check the position of the controller’s mode switch or the status bar of the FlexPendant.

Operational mode changes are also logged in the event log.

The mode switch

The mode switch should be in the position as illustrated: xx0300000466

A

B

C

D

E

Two position mode switch

Three position mode switch

Automatic mode

Manual reduced speed mode

Manual full speed mode

Step

1.

2.

Action

To switch from manual to automatic mode

To switch from automatic to manual mode

Info

detailed in

Switching from manual to automatic mode on page 234

.

detailed in

Switching from automatic to manual mode on page 235

.

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225

7 Running in production

7.5.1. Present operating mode

Continued

Viewing present mode on the FlexPendant

On the FlexPendant, you can view the present operating mode in the status bar. An example of the status bar is shown below: en0300000490

D

E

F

A

B

C

Operator window

Operating mode

Active system

Controller state

Program state

Mechanical units, active is highlighted

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7 Running in production

7.5.2. About the automatic mode

7.5.2. About the automatic mode

What is the automatic mode?

In automatic mode the enabling device is disconnected so that the robot can move without human intervention.

A robot system in production normally runs in the automatic mode. This mode enables controlling the robot system remotely, for instance by using the controller’s I/O signals. An input signal may be used to start and stop a RAPID program, another to activate the robot’s motors.

There are also additional safeguarding mechanisms active in automatic mode, not used in manual mode, to increase safety.

Tasks you normally perform in the automatic mode

In automatic mode you normally:

• start and stop processes.

• load, start and stop RAPID programs.

• return the robot to its path when you return to operation after an emergency stop.

• backup the system.

• restore backups.

• tune paths.

• clean tools.

• prepare or replace work objects.

• perform other process oriented tasks.

A well designed system allows you to perform tasks safely and without affecting the running process. In such a system you can at any time enter safeguarded space temporarily having the process stopped by safeguarding mechanisms while you perform the tasks necessary. When you leave safeguarded space the process is resumed.

Please consult your plant or cell documentation for details on process oriented tasks.

CAUTION!

If the robot system is under remote control actions such as starting or stopping process applications and RAPID programs may be overridden. Path tuning may also be disturbed.

In such case perform the mentioned tasks in manual mode.

Limitations in automatic mode

Jogging is not possible in automatic mode. There may also be other specific tasks that you should perform in manual mode to make sure only you are in control of the robot and its movements.

Please consult your plant or system documentation to find out which specific tasks should not be performed in manual mode.

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7 Running in production

7.5.3. About the manual mode

7.5.3. About the manual mode

What is the manual mode?

In manual mode the robot can only move in a reduced and safe speed, and only under manual control.

You need to press the enabling device to activate the robot’s motors. The manual mode is most often used when creating programs and when commissioning a robot system.

In some robot systems, there are two manual modes, the normal manual mode, sometimes referred to as Manual Reduced Speed Mode, and then there is a Manual Full Speed Mode.

What is the manual full speed mode?

In manual full speed mode the robot can move in programmed speed but only under manual control.

You need to press the enabling device and the hold-to-run button to activate the robot’s motors. The manual full speed mode is most often used when testing programs and commissioning a robot system.

Note that the manual full speed mode is not available in all robot systems.

Tasks you normally perform in manual mode

In manual mode you normally:

• jog the robot back on its path when you return to operation after an emergency stop.

• correct the value of I/O signals after error conditions.

• create and edit RAPID programs.

• tune programmed positions.

Safety in manual mode

When in manual mode some safeguarding mechanisms are disabled since the robot in this mode often is operated with personnel in close proximity. Maneuvering an industrial robot is potentially dangerous and therefore maneuvers should be performed in a controlled fashion, in manual mode the robot is operated in reduced speed, normally 250 mm/s.

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7 Running in production

7.5.4. Start up in automatic mode

7.5.4. Start up in automatic mode

DANGER!

When started the robot may move without warning.

Make sure no personnel are in safeguarded space before you turn on power.

When should I start up in automatic mode?

Start the robot system in automatic mode to resume or start a process or program automatically. Use manual mode for a robot system not yet taken in production or for any other task you need to perform that requires manual mode.

The exact procedure may differ from system to system depending on customizations and programs specifically created for you.

Please consult your plant or cell documentation for details on how to start your specific robot system.

Start up in automatic mode

Step

1.

Action

Set the mode switch in the automatic position.

Illustration

2.

Turn on the mains power by setting the switch in the on position.

en0400000794

Exceptions

3.

4.

Did the system start up without errors?

If yes, then the procedure is completed.

If no, abort.

After being started, the system will normally be in a safe standby state with motors off awaiting further actions.

en0400000793

In automatic mode it is possible to start a RAPID program and turn motors on remotely. This means that the system will never enter a safe standby state and the robot may move at any time.

Please consult your plant or cell documentation for details on how your system is configured.

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229

7 Running in production

7.5.4. Start up in automatic mode

Continued

Manually resume process

Follow this procedure to manually resume the program when the system is not configured for remote restart.

Step

1.

Action

On the controller, press the Motors On button to activate the robots motors.

Illustration

Limitations

2.

3.

en0400000795

On the FlexPendant, press the Start button to start the program.

Did the program start without errors?

If yes, the procedure is completed.

If no, consult your plant or cell documentation for fault tracing guidelines.

Error handling is detailed in

Trouble shooting manual

- IRC5

.

It may not always be desired to resume or start a program. The work piece currently in process should perhaps be discarded, or an ongoing glue or weld should perhaps not be continued.

Please consult your plant or cell documentation for guidelines.

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7 Running in production

7.5.5. Start up in manual mode

7.5.5. Start up in manual mode

When should I start the system in manual mode?

Start the system in manual mode when there is no process or program to be resumed or started or when you need to perform operations not possible in automatic mode such as program editing and jogging.

Start up in manual mode

Step

1.

Action

Set the mode switch in the manual mode position.

Illustration

2.

Turn on the main power by setting the switch in the on position.

en0400000807

3.

4.

Did the system start up without errors?

If yes, then the procedure is completed.

If no, please consult your plant or cell documentation for fault tracing guidelines.

en0400000793

Error handling is detailed in

Trouble shooting manual

- IRC5

.

After being started, the system will be in a safe standby state awaiting further actions.

Where do I go from here?

If you want to...

create RAPID programs jog the robot work with or change tools, work objects or payloads

...then read...

Handling of programs on page 165

.

Introduction to jogging on page 105

.

Selecting tool, work object, and payload on page 112

.

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7 Running in production

7.5.6. Running programs in automatic mode

7.5.6. Running programs in automatic mode

Running programs in automatic mode

This section details how to run programs in automatic mode.

Step

1.

Action

Switch the robot to Automatic Mode.

Info

How to do this is detailed in section

Switching from manual to automatic mode on page 234

2.

4.

5.

3.

xx

Before running the robot, please observe the safety information in

section

DANGER - Moving manipulators are potentially lethal! on page 18

Select the program to be started.

How to load a program is detailed in

section

Loading an existing program on page 166

.

Choose in what mode to start the program and start.

Press the Start button on the

FlexPendant.

All FlexPendant buttons are shown in

section

page 38

What is a FlexPendant? on

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7 Running in production

7.5.7. Running programs in manual mode

7.5.7. Running programs in manual mode

Running programs in manual mode

This section details how to run programs in manual mode.

Step

1.

Action

Switch the robot to manual mode.

Info

How switch to manual mode is described in section

Switching from automatic to manual mode on page

235

.

2.

3.

4.

5.

xx

DANGER!

Before running the robot, please observe the safety information in section

DANGER - Moving manipulators are potentially lethal! on page 18

Select the program to be started.

Select in what run or step mode to start the program.

How to open a program is detailed in

section

Loading an existing program on page 166

.

How to select start mode is detailed in section

How to use the hold-to-run function on page 196

.

Press and hold the enabling device and then press the Start button on the

FlexPendant.

All FlexPendant buttons are shown in section

What is a FlexPendant? on page 38

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7 Running in production

7.5.8. Switching from manual to automatic mode

7.5.8. Switching from manual to automatic mode

When should I put the system in automatic mode?

Put the system in automatic mode when you have a process application or a RAPID program that is ready to be run in production.

DANGER!

When put in automatic mode the robot may move without warning.

Make sure no personnel are in safeguarded space before you change operating mode.

Switching from manual to automatic mode

Step

1.

Action

Set the mode switch in the automatic position.

A mode change dialog is displayed.

Illustration

2.

3.

xx0300000467

Tap OK to close the dialog.

If you change the switch back to manual mode the dialog will be closed automatically.

Did the system change mode without errors?

If yes, then resume or start the process application or RAPID program.

If no, stop and troubleshoot the problem.

How to start programs is described in

Starting programs on page 219

.

NOTE!

If your specific system uses a distributed operators panel, controls and indicators may not be placed exactly as described in this manual. Please consult your plant or cell documentation for details.

Controls and indicators do however look and function the same way.

When can I start using the robot system?

As long as the mode change dialog is displayed programs cannot be started and the robot’s motors cannot be activated either manually or remotely.

Exceptions

In automatic mode it is possible to start a RAPID program and turn motors on remotely. This means that the system will never enter a safe standby state and the robot may move at any time.

Please consult your plant or cell documentation for details on how your system is configured.

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7.5.9. Switching from automatic to manual mode

7.5.9. Switching from automatic to manual mode

Switching from automatic to manual mode

Step

1.

Action

Set the mode switch in the manual position.

Illustration

2.

Did the system change mode without errors?

If yes, then this procedure is completed.

If no, try to locate the error.

xx0300000468

Error handling is detailed in

Trouble shooting manual - IRC5

.

NOTE!

If your specific system uses a distributed operators panel, controls and indicators may not be placed exactly as described in this manual. Please consult your plant or cell documentation for details.

Controls and indicators do however look and function the same way.

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7 Running in production

7.5.10. Switching to manual full speed mode

7.5.10. Switching to manual full speed mode

When should I use the manual full speed mode?

Use full speed manual mode when the program is to be tested at full speed.

The manual full speed mode allows you to run the program at full speed while still having access to all the available debugging functions of the program editor.

DANGER!

Testing at full speed is dangerous.

Make sure no personnel are in safeguarded space when starting the program.

Switching to manual full speed mode

Step

1.

2.

Action Info

Set the mode switch to the manual full speed position.

Did the system change mode without errors?

If yes, then this procedure is completed.

If no, try to locate the error.

Error handling is detailed in

Trouble shooting manual - IRC5

.

FlexPendant alert

When changing mode a dialog is displayed on the FlexPendant to alert you about the change of mode. Tap OK to close the dialog.

If you change the switch back to the previous mode the dialog will be closed automatically and there will be no change in mode.

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8 Handling inputs and outputs, I/O

8.1. Inputs and Outputs, I/O

8 Handling inputs and outputs, I/O

8.1. Inputs and Outputs, I/O

Overview

I/O signal properties is used to view the input and output signals and their values. Signals are configured with system parameters, see section

Configuring system parameters on page 270

.

Viewing signals

This section details how to view a list of all signals.

Step

1.

2.

Action

On the ABB menu tap Inputs and Outputs.

The list of Most Common I/O signals is displayed.

Tap View and then All signals to change the selection of signals in the list.

en0400000770

Related information

Simulating and changing signal values on page 238

.

Configuring Most Common I/O on page 289

.

Configuring system parameters on page 270

.

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8 Handling inputs and outputs, I/O

8.2. Simulating and changing signal values

8.2. Simulating and changing signal values

Simulating and changing signal values

A signal can be changed into a simulated signal and the value of the signal can be changed.

More information on how to change the signal’s properties is described in the section Control

Panel,

Configuring Most Common I/O on page 289

.

Step

1.

2.

3.

4.

Action

On the ABB menu, tap I/O.

A list of most common signals is displayed. See section

Configuring Most

Common I/O on page 289

.

Tap on a signal.

Tap on Simulate to change the signal into a simulated signal.

Tap on Remove Simulation to remove the simulation from the signal.

Tap on 123... to change the signal’s value.

The soft numeric keyboard is displayed. Enter the new value and tap OK.

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8 Handling inputs and outputs, I/O

8.3. Viewing signal group

8.3. Viewing signal group

Viewing signal group

This section details how to view signal groups.

Step

1.

2.

3.

Action

On the ABB menu, tap I/O.

A list of most common signals is displayed. See section

Configuring Most

Common I/O on page 289

.

In the View menu, tap Groups.

Tap on the signal group’s name in the list and then tap Properties. Or tap twice on the signal group’s name.

The signal group’s properties is displayed.

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8 Handling inputs and outputs, I/O

8.4. Safety I/O signals

8.4. Safety I/O signals

General

In the controller’s basic and standard form, certain I/O signals are dedicated to specific safety functions. These are listed below with a brief description of each.

All signals can be viewed in the I/O menu on the FlexPendant.

Safety I/O signals

The list below contains the safety I/O signals as used by the standard system.

240

Signal name

ES1

ES2

SOFTESI

EN1

EN2

AUTO1

AUTO2

MAN1

MANFS1

MAN2

MANFS2

USERDOOV

LD

MONPB

AS1

AS2

SOFTASI

GS1

GS2

Description

Bit value condition

From - To

Emergency stop, chain

1

1 = Chain closed

Emergency stop, chain

2

1 = Chain closed

Soft Emergency stop 1 = Soft stop enabled From panel board to main computer

Enabling device1&2, chain 1

1 = Enabled From panel board to main computer

1 = Enabled Enabling device1&2, chain 2

Op mode selector, chain 1

1 = Auto selected

From panel board to main computer

From panel board to main computer

1 = Auto selected

From panel board to main computer

From panel board to main computer

Op mode selector, chain 2

Op mode selector, chain 1

Op mode selector, chain 1

Op mode selector, chain 2

1 = MAN selected

1 = Man. full speed selected

1 = MAN selected

From panel board to main computer

From panel board to main computer

From panel board to main computer

From panel board to main computer

Op mode selector, chain 2

Over load, user DO

Motors-on pushbutton

Auto stop, chain 1

1 = Man. full speed selected

1 = Error, 0 = OK

1 = Pushbutton pressed

1 = Chain closed

From panel board to main computer

From panel board to main computer

From panel board to main computer

From panel board to main computer

Auto stop, chain 2

Soft Auto stop

1 = Chain closed From panel board to main computer

1 = Soft stop enabled From panel board to main computer

General stop, chain 1 1 = Chain closed From panel board to main computer

General stop, chain 2 1 = Chain closed From panel board to main computer

Continues on next page

3HAC 16590-1 Revision: B

8 Handling inputs and outputs, I/O

8.4. Safety I/O signals

Continued

Signal name

Description

Bit value condition

From - To

SOFTGSI

SUPES1

SUPES2

SOFTSSI

CH1

Soft General stop 1 = Soft stop enabled From panel board to main computer

Superior stop, chain1 1 = Chain closed From panel board to main computer

Superior stop, chain2

Soft Superior stop

All switches in run chain 1 closed

1 = Chain closed From panel board to main computer

1 = Soft stop enabled From panel board to main computer

1 = Chain closed From panel board to main computer

CH2

ENABLE1

All switches in run chain 2 closed

Enable from MC (read back)

ENABLE2_1 Enable from AXC1

1 = Chain closed From panel board to main computer

1 = Enable, 0 = break chain 1

From panel board to main computer

ENABLE2_2 Enable from AXC2

1 = Enable, 0 = break chain 2

From panel board to main computer

1 = Enable, 0 = break chain 2

From panel board to main computer

ENABLE2_3

ENABLE2_4

PANFAN

PANEL24OV

LD

DRVOVLD

DRV1LIM1

Enable from AXC3

Enable from AXC4

1 = Enable, 0 = break chain 2

From panel board to main computer

1 = Enable, 0 = break chain 2

From panel board to main computer

Superv. of fan in

Control module

Overload, drive modules

Read back of chain 1 after limit switches

1 = OK, 0 = Error

Overload, panel 24V 1 = Error, 0 = OK

From panel board to main computer

From panel board to main computer

1 = Error, 0 = OK From panel board to main computer

1 = Chain 1 closed From axis computer to main computer

DRV1LIM2

DRV1K1

DRV1K2

DRV1EXTCO

NT

DRV1PANCH

1

Read back of contactor

K2, chain 2

External contactors closed

Drive voltage for contactor-coil 1

1 = K2 closed

1 = Contactors closed

From axis computer to main computer

From axis computer to main computer

1 = Voltage applied From axis computer to main computer

DRV1PANCH

2

Drive voltage for contactor-coil 2

DRV1SPEED Read back of op. mode selected

1 = Voltage applied From axis computer to main computer

0 = Man. mode low speed

From axis computer to main computer

DRV1TEST1

Read back of chain 2 after limit switches

Read back of contactor

K1, chain 1

1 = Chain 2 closed From axis computer to main computer

1 = K1 closed From axis computer to main computer

A dip in run chain 1 has been detected

DRV1TEST2 A dip in run chain 2 has been detected

Toggled

Toggled

From axis computer to main computer

From axis computer to main computer

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8 Handling inputs and outputs, I/O

8.4. Safety I/O signals

Continued

Signal name

Description

Bit value condition

From - To

SOFTESO

SOFTASO

SOFTGSO

SOFTSSO

MOTLMP

ENABLE1

TESTEN1

DRV1CHAIN

1

DRV1CHAIN

2

Soft Emergency stop

Soft Auto stop

1 = Set soft E-stop From main computer to panel board

1 = Set soft Auto stop From main computer to panel board

Soft General stop

Soft Superior stop

Motors-on lamp

Enable1 from MC

Test of Enable1

Signal to interlocking circuit

Signal to interlocking circuit

DRV1BRAKE Signal to brakerelease coil

1 = Set soft General stop

1 = Set soft Sup. Estop

1 = Lamp on

From main computer to panel board

From main computer to panel board

1 = Enable, 0 = break chain 1

From main computer to panel board

1 = Start test

From main computer to panel board

1 = Close chain 1

From main computer to panel board

From main computer to axis computer 1

1 = Close chain 2

1 = Release brake

From main computer to axis computer 1

From main computer to axis computer 1

242 3HAC 16590-1 Revision: B

9 Handling the event log

9.1. Accessing the event log

9 Handling the event log

9.1. Accessing the event log

Event log

Open the event log to:

• view all present entries.

• study specific entries in detail.

• handle the log entries, such as saving or deleting.

The log can be printed by using RobotStudio

Online

.

Open and close the event log

This section details how to open the event log.

Step

1.

2.

3.

4.

5.

Action

Tap the status bar.

The status window is displayed.

Tap Event Log.

The event log is displayed.

If the log contents do not fit into a single screen, it can be scrolled.

Tap a log entry to view the event message.

Tap the status bar again to close the log.

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9 Handling the event log

9.2. Deleting log entries

9.2. Deleting log entries

Why should I delete log entries?

Logs can be deleted to increase available disk space. Deleting log entries is often a good way to trace faults since you remove old and insignificant log entries not related to the problem you are trying to solve.

Delete all log entries

Step

1.

2.

3.

4.

Action

Tap the status bar, then the Event Log tab to open the event log.

On the Viewmenu, tap Common.

Tap Delete and then Delete all logs.

A confirmation dialog is displayed.

Tap Yes to delete, or No to keep the log intact.

Delete log entries of a specific category

Step

1.

2.

3.

4.

Action

Tap the status bar, then the Event Log tab to open the event log.

On the View menu, tap the category of choice.

Tap Delete and then Delete log.

A confirmation dialog is displayed.

Tap Yes to delete, or No to keep the log intact.

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9 Handling the event log

9.3. Saving log entries

9.3. Saving log entries

Why should I save log entries?

You should save log entries when:

• you need to clear the log but want to keep the current entries to be viewed later.

• you want to send log entries to support to solve a problem.

• you want to keep log entries for future reference.

NOTE!

The log can keep up to 20 entries per category and up to 1000 entries in the all events list.

When the buffer is full the oldest entries will be overwritten and lost.

There is no way to retrieve these lost log entries.

Save all log entries

This section details how to save all log entries.

Step

1.

2.

3.

4.

5.

Action

Tap the status bar to open the event log.

Tap Save all logs as.

The file dialog is displayed.

If you want to save the log in a different folder, locate and open the folder.

In the File name box, type a name for the file.

Tap Save.

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9 Handling the event log

9.3. Saving log entries

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10 Systems

10.1. About systems

10 Systems

10.1. About systems

Systems

The FlexController can have one or more systems installed. These are created and managed using RobotStudio Online.

On the FlexPendant you can backup, restart, and select systems, and make modifications to configurations using the system parameters.

For more information on how to create or work with systems, please read Operator’s manual

- RobotStudio Online.

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10 Systems

10.2.1. What is “the memory”?

10.2 Memory and file handling

10.2.1. What is “the memory”?

Overview

When using the term “memory”, a number of things may be implied:

•

The main computer RAM memory

•

The system hard disk drive or flash disk drive

•

The hard disk of some other unit connected to the same LAN as the robot system, serving as a storage for software.

Main computer RAM memory

The RAM memory is the main computer primary memory located on the computer motherboard. The memory is used by the processor during all program execution.

The contents of the RAM memory during operation is described in section

The structure of the main computer RAM memory contents on page 249

System hard/flash disk drive

This is the main mass storage unit of the control module, and is located in the front of the

Control Module. Depending on controller version, it may be a hard disk drive or a flash disk drive and may vary in size.

It contains all necessary software for operating the robot, and is the unit on which the

RobotWare is installed.

When starting up, data is loaded into the RAM memory from the disk drive.

When powering down, the image.bin is saved here. The contents of the image.bin is described in section

The structure of the main computer RAM memory contents on page 249

LAN unit

This may be used as extra mass storage device if the one in the controlled is not sufficient. It is not normally considered a part of the robot system

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10 Systems

10.2.2. The structure of the main computer RAM memory contents

10.2.2. The structure of the main computer RAM memory contents

General

This section describes what the main computer RAM memory contains during normal operation.

The term “RAM memory” means the main computer primary memory, i.e. the memory modules with which the main computer processor works during normal operation.

The generic term “memory” is described in section

What is “the memory”? on page 248

Illustration of the RAM memory

Each part of the illustration is described in the table below.

en0500001446

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249

10 Systems

10.2.2. The structure of the main computer RAM memory contents

Continued

Parts

250

Part Function

RAM memory The main computer memory modules, located on the computer motherboard. The processor reads and writes to this memory during program execution.

The size of the RAM memory may vary, but increasing the size will not

improve computer performance unless a number of hard- and software changes are made to the robot system.

image.bin

When the system is powered OFF, intentionally or due to power failure, the image.bin file is saved to the controller hard/flash disk.

It is an internal file, created by the system during operation, usually invisible to the user.

When performing a “warm start” of the system, the complete image.bin file is reloaded into the RAM memory. Other types of restarts may start with another system, etc, which is described in the

Operator’s manual - IRC5 with

FlexPendant

.

ctrl.bin

SMB board

Controller hard/flash disk

This file contains, among other things:

• robot identity data

• calibration data

• SIS data

• duty timer data

The file is stored on the SMB board on robot delivery. Data may then be transferred to the controller as detailed in the

Operator’s manual - IRC5 with

FlexPendant

.

NOTE that the ctrl.bin file is not stored in the system specific file on the hard/ flash disk drive. This means that all data in the file will be retained even if the system software is updated or in any other way replaced.

The SMB board (serial measurement board) is normally fitted on the mechanical unit, and contains among other things, data from the ctrl.bin file.

How to handle the data on the SMB board, moving data between SMB and controller, etc is detailed in the

Operator’s manual - IRC5 with FlexPendant

.

The main mass storage unit of the control module, located in the Computer

Unit. Depending on controller version, it may be a hard disk drive or a flash disk drive and may vary in size.

It contains all necessary software for operating the robot, and is the unit on which the RobotWare is installed.

When starting up, data is loaded into the RAM memory from the disk drive.

When powering down, the image.bin file is automatically saved here.

RAPID code This section contains all executable RAPID code, whether written by ABB or the customer.

Configuration data

This data is basically the contents of the configuration files:

• proc.cfg

• moc.cfg

• sio.cfg

• mmc.cfg

• sys.cfg

Each file contains the settings made when creating and defining the system, options etc.

The configuration files may not be changed after creation, but their contents may be checked as detailed in the Trouble Shooting Manual - IRC5. When changing the contents of the configuration files, ABB strongly recommends using the tool RobotStudio

Online

to reduce the risk of introducing errors.

Continues on next page

3HAC 16590-1 Revision: B

10 Systems

10.2.2. The structure of the main computer RAM memory contents

Continued

Part Function

Texts

Event logs

Some of the texts used by the system during operation, in all languages selected when creating the system.

All events logged in all event logs.

This means that the logs will be saved even if a power failure occurs, which in turn, simplifies finding the fault causing the power failure.

Internal states This is data recording the state and position of all robot axes, all I/O, the state of each manipulator connected to a Multimove system, etc.

This data is constantly updated during operation. This enables the system to instantly return to it’s previous state if the system for any reason stops, there is a power failure or the robot collides with an obstacle etc.

Calibration data

SIS

This is calibration data for one robot, i.e. all data describing the calibration position for all six axes of one robot.

This is service data related to the SIS system (Service Interval System).

This means that SIS data will be kept by the robot even if it’s controller is replaced.

Duty timer This is the Duty timer data.

This means that duty timer count will be kept by the robot even if it’s controller is replaced.

“My system” This is the directory in which the RobotWare is stored after installation. The image file is stored in the directory “Internal”.

NOTE that the ctrl.bin file is not stored here, which means that the contents of the image.bin file will be retained even if updating the system software during operation.

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10 Systems

10.2.3. File handling

10.2.3. File handling

File handling and storing

Backups, programs, and configurations etc. are saved as files in the robot system. These files are handled either in a specific FlexPendant application, such as the Program editor, or using the FlexPendant Explorer.

Files can be stored on a number of different drives, or memory devices, such as:

•

Controller hard disk

•

Portable PC

• USB device

•

Other network drives

These drives are used the same way and available in the FlexPendant Explorer or when saving or opening files using an application on the FlexPendant.

USB memory information

IRC5 is equipped with a USB port on the controller module, see chapter

Buttons on the controller on page 47

.

A USB memory is normally detected by the system and ready to use within a few seconds from plugging in the hardware. A plugged in USB memory is automatically detected during system start up.

It is possible to plug in and unplug a USB memory while the system is running. However, observing the following precautions will avoid problems:

•

Do not unplug a USB memory immediately after plugging in. Wait at least five seconds, or until the memory has been detected by the system.

• Do not unplug a USB memory during file operations, such as saving or copying files.

Many USB memories indicates ongoing operations with a flashing LED.

•

Do not unplug a USB memory while the system is shutting down. Wait until shutdown is completed.

Please also note the following limitations with USB memories:

•

There is no guarantee that all USB memories are supported.

• Some USB memories have a write protection switch. The system is not able to detect if a file operation failed due to the write protection switch.

Related information

For more information on trouble shooting, see Trouble shooting manual - IRC5.

What is “the memory”? on page 248

.

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10 Systems

10.3.1. Restart overview

10.3 Restart procedures

10.3.1. Restart overview

When do I need to restart a running controller?

ABB robot systems are designed to operate unattended for long times. There is no need to periodically restart functioning systems.

Restart the robot system when:

• new hardware has been installed.

• the robot system configuration files have been changed.

• a new system has been added and is to be used.

• a system failure (SYSFAIL) has occurred.

Restart types

A number of restart types are available:

Situation: Restart type: Detailed in section:

You want to restart and use the current system.

All programs and configurations will be saved.

W-start (Warm restart)

You want to restart and select another system.

The Boot application will be launched at startup.

X-start (Xtra restart)

Restart and use the current system (warm start) on page 257

.

Restart and select another system (X-start) on page 258

.

Restart and delete the current system (C-start) on page 259

.

You want to switch to another installed system

or install a new system and, at the same time, remove the current system from the controller.

Warning! This can not be undone. The system

and the RobotWare system package will be deleted.

C-start (Cold restart)

You want to delete all user loaded RAPID programs.

Warning! This can not be undone.

P-start

You want to return to the default system settings.

Warning!This will remove all user defined

programs and configurations from memory and restart with default factory settings.

I-start

(Installation restart)

You want to restart the current system using the system data from most recent successful shut down.

B-start

You want to shut down and save the current system and shut down the main computer.

Shutdown

Restart and delete programs and modules

(P-start) on page 260

.

Restart and return to default settings (I-start) on page 261

.

Restart from previously stored system data (Bstart) on page 262

.

Shutting down on page

69

.

Related information

More information about the different restart procedures is also described in Trouble shooting

manual - IRC5.

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10 Systems

10.3.2. Using the boot application

10.3.2. Using the boot application

Boot application

The boot application is primarily used to start up the system when no RobotWare is installed, but may also be used for other purposes, such as changing the system to start. You can also use RobotStudio Online, see

Operator’s manual - RobotStudio Online

.

Purpose of the boot application

The boot application is installed in the controller at delivery and may be used to:

• install systems

• set or check network settings

• select a system/switch between systems from the mass storage memory

• load the system from USB memory units or network connections

The illustration shows the boot application main screen. The buttons and functions available are described below.

en0400000894

Installing a system

This procedure may take several minutes.

Step

1.

2.

Action Info

You may reach the boot application by performing an X-start.

In the boot application, tap Install

System.

A dialog box is displayed urging you to connect a USB memory.

How to perform an X-start is detailed in

section

Restart and select another system (X-start) on page 258

.

Systems are created using the System

Builder in RobotStudio Online. See

Operator’s manual - RobotStudio

Online

.

254

Continues on next page

3HAC 16590-1 Revision: B

10 Systems

10.3.2. Using the boot application

Continued

Step

3.

4.

5.

6.

Action Info

Connect a USB memory containing a system to the computer unit USB port.

How to load a system to the USB memory is detailed in section

Creating boot media

in

Operator’s manual -

RobotStudio Online

.

The USB port is shown in section

Buttons on the controller on page 47

.

Tap Continue to proceed.

Tap Cancel to abort.

The system is read from the USB memory, and a dialog box is displayed, urging you to restart.

Tap OK.

The USB memory may be disconnected at this point.

Tap Restart Controller and then tap

OK.

The controller is now restarted and the system from the USB memory is installed. The restart may take several minutes.

Boot application settings

The boot application settings contain IP and network settings.

Step

1.

2.

Action Info

You may reach the boot application by performing an X-start.

How to perform an X-start is detailed in section

Restart and select another system

(X-start) on page 258

.

In the boot application, tap Settings.

3.

en0400000902

Make the appropriate selections:

• Use no IP address

• Obtain IP address automatically

• Use the following settings

Use the numerical keyboard to enter the desired values.

How to make these selections is detailed in

section

Set up the network connection on page 54

.

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10 Systems

10.3.2. Using the boot application

Continued

Step

4.

5.

Action

Tap Service PC information to display network settings to be used when connection a service PC to the controller’s service port.

Tap FlexPendant to display FlexPendant software versions.

Tap Advanced to display the boot loader version.

Info

Selecting system

Step

1.

2.

3.

4.

Action Info

You may reach the boot application by performing an X-start.

How to perform an X-start is

detailed in section

Restart and select another system

(X-start) on page 258

.

In the boot application, tap Select System.

A dialog box is displayed showing the available installed systems.

Tap the system to be selected and then Select.

The selected system is displayed in the box

Selected System.

Tap Close.

A dialog box is shown urging you to restart to be able to use the selected system.

Restarting controller

Step

1.

2.

3.

Action Info

You may reach the boot application by performing an X-start.

How to perform an X-start is detailed in section

Restart and select another system

(X-start) on page 258

.

In the boot application, tap Restart System.

A dialog box is displayed specifying the selected system.

Tap OK to restart using the selected system or

Cancel to abort.

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10 Systems

10.3.3. Restart and use the current system (warm start)

10.3.3. Restart and use the current system (warm start)

What happens with my current system?

The current system will be stopped.

All system parameters and programs will be saved to an image file.

During the restart process the system’s state will be resumed. Static and semistatic tasks will be started. Programs can be started from the point they where stopped.

Restarting this way will activate any configuration changes entered using RobotStudio

Online

.

Restart and use the current system

This section describes how to restart and use the current system.

Step

1.

2.

Action Info

On the ABBmenu, tap Restart.

The restart dialog is displayed.

Tap Warm Start to restart the controller using the current system.

To select another type of start, tap

Advanced. Detailed information about advanced starts is given in

Restart overview on page 253

.

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10 Systems

10.3.4. Restart and select another system (X-start)

10.3.4. Restart and select another system (X-start)

What happens with my current system?

The current system will be stopped.

All system parameters and programs will be saved to an image file, so that the system’s state can be resumed later.

Restart and select another system

This section describes how to restart and select another system.

Step

1.

2.

3.

4.

5.

6.

7.

8.

Action Info

Make sure the power to the controller cabinet is switched on.

On the ABBmenu, tap Restart.

The restart dialog is displayed.

Tap Advanced... to select restart method.

The select restart method dialog is displayed.

Tap X-start, then tap OK.

A dialog letting you confirm that you really want to restart is displayed.

Tap X-Start to restart the controller.

The controller is restarted. After the startup procedure the boot application is started.

Use the boot application to select system.

How to use the boot application is

detailed in

Using the boot application on page 254

.

Tap Close, then OK to return to the boot application.

Tap Restart to restart the controller using the selected system.

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10 Systems

10.3.5. Restart and delete the current system (C-start)

10.3.5. Restart and delete the current system (C-start)

What happens with my current system?

Your current system will be stopped.

All contents, backups and programs, in the system directory will be deleted. This means it will be impossible to resume this system’s state in any way. A new system must be installed using RobotStudio

Online

.

Restart and delete the current system

This section describes how to restart and delete the current system.

Step

1.

2.

3.

4.

5.

Action Info

On the ABBmenu, tap Restart.

The restart dialog is displayed.

Tap Advanced... to select restart method.

The select restart method dialog is displayed.

Tap C-start, then tap OK.

A dialog letting you confirm that you want to restart is displayed.

Tap C-start to restart the controller.

A dialog letting you confirm that you want to restart is displayed.

Perform any of the following procedures:

• Select an already installed system and restart.

• Install another system from

RobotStudio

Online

or from a USB memory.

How to restart and select another system is described in section

Restart and select another system (X-start) on page 258

.

RobotStudio

Online

is described in

Operator’s manual - RobotStudio

Online

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10 Systems

10.3.6. Restart and delete programs and modules (P-start)

10.3.6. Restart and delete programs and modules (P-start)

What happens with my current system?

After restart the system’s state will be resumed except for manually loaded programs and modules. Static and semistatic tasks are started from the beginning, not from the state they had when the system was stopped.

Modules will be installed and loaded in accordance with the set configuration. System parameters will not be affected.

Restart and delete programs and modules

This section describes how to restart and delete user loaded programs and modules.

Step

1.

2.

3.

4.

Action

On the ABBmenu, tap Restart.

The restart dialog is displayed.

Tap Advanced... to select restart method.

The select restart method dialog is displayed.

Tap P-start, then tap OK.

A dialog letting you confirm that you really want to restart is displayed.

Tap P-start to restart the controller.

The controller is restarted using the current system. After the startup procedure no programs or modules are open.

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10 Systems

10.3.7. Restart and return to default settings (I-start)

10.3.7. Restart and return to default settings (I-start)

What happens to my current system?

After restart, the system’s state will be resumed but any changes done to system parameters and other settings will be lost. Instead, system parameters and other settings are read from the originally installed system on delivery.

For example, this returns the system to the original factory system state.

Restart and return to default settings

This section describes how to restart and return to default settings.

Step

1.

2.

3.

4.

Action

On the ABBmenu, tap Restart.

The restart dialog is displayed.

Tap Advanced... to select restart method.

The select restart method dialog is displayed.

Tap I-start, then tap OK.

A dialog letting you confirm that you really want to restart is displayed.

Tap I-start to restart the controller.

The controller is restarted using the current system. Changes to system parameters and other settings are lost.

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10 Systems

10.3.8. Restart from previously stored system data (B-start)

10.3.8. Restart from previously stored system data (B-start)

What happens with my current system?

The current system is in system failure mode since the previous session was shut down without saving the image file correctly. All changes made to the system before the shut down has been lost. Therefore, the system needs to be restarted from the most recent successful shut down or load another system.

Note that all changes made to the system data since the previous session has been lost.

Restart from previously stored system data

This section describes how to restart from previously stored image file.

Step

1.

2.

3.

4.

Action

On the ABBmenu, tap Restart.

The restart dialog is displayed.

Tap Advanced... to select restart method.

The select restart method dialog is displayed.

Tap B-start, then tap OK.

Tap B-start to restart the controller.

The controller is restarted using the system data from the most recent successful shut down.

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10 Systems

10.3.9. Reflashing firmware and FlexPendant

10.3.9. Reflashing firmware and FlexPendant

Overview of reflashing

After replacing hardware units, such as axis computer, buses, etc., or installing newer versions of RobotWare, the system will automatically attempt reflashing the unit in order to maintain hardware/software compatibility.

Reflashing is loading appropriate firmware (hardware specific software) onto a specific unit running this software during operation.

If RobotWare is upgraded on the controller, then the FlexPendant will reflash, i.e. update to the new version, when connected.

Note that performing any such replacements/updates might require running firmware versions not available! To avoid jeopardizing the function of the system, ABB recommends using the same versions as earlier, unless these are unavailable.

The units currently using the reflash function are:

•

Contactor interface board

• Drive units

•

FlexPendant

• Profibus master

•

Axis computer

• Panel board

Reflashing process

The automatic reflashing process, described below, must not be disturbed by switching off the controller while running:

Step

1.

2.

3.

4.

Event Info

When the system is restarted, the system checks the versions of the firmware used. These are checked against the hardware versions used.

If the hardware and firmware versions do not match, the system restarts itself automatically while going to a specific

Update Mode.

Was an appropriate firmware version found?

If YES, the reflash will proceed.

If NO, the system will stop. Proceed as detailed in section

Reflashing firmware failed

in the Trouble shooting manual -

IRC5.

During the Update Mode, an attempt is made to download appropriate firmware onto the hardware while a message is very briefly displayed on the

FlexPendant.

In either case, a message is very briefly displayed on the FlexPendant and stored in the event log.

The actual reflashing may take a few seconds or up to a few minutes, depending on the hardware to be reflashed.

After performing a successful reflash, the system restarts.

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263

10 Systems

10.3.9. Reflashing firmware and FlexPendant

Continued

Step

5.

6.

Event

Another check is made for any additional hardware/firmware mismatches.

Was any additional mismatches found?

If YES, the process is repeated until none are found.

If NO, the process is complete.

Info

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10 Systems

10.4.1. What is saved on backup?

10.4 Backup and restore systems

10.4.1. What is saved on backup?

General

When performing a backup, or restoring a previously made backup, only certain data is dealt with. This section is a specification and description of these.

What is saved?

The backup function saves all system parameters, system modules, and program modules in a context.

The data is saved in a directory specified by the user. The directory is divided into four subdirectories, Backinfo, Home, Rapid, and Syspar. System.xml is also saved in the ../backup

(root directory) it contains user settings.

Backinfo consists of the files backinfo.txt, key.id, program.id and system.guid, template.guid, keystr.txt.

The restore part uses backinfo.txt when the system is restored. This file must never be edited by the user! The files key.id and program.id may be used to recreate a system, using

RobotStudio

Online

, with the same options as the backed up system. The system.guid is used to identify the unique system the backup was taken from. The system.guid and/or template.guid is used in the restore to check that the backup is loaded to the correct system. If the

system.guid and/or template.guid do not match, the user will be informed.

Home

Rapid

SysPar en0400000916 a copy of the files in the HOME directory.

consists of a subdirectory for each task configured. Every task has one directory for program modules and one for system modules.

The first directory will keep all installed modules. More information on loading modules and programs is given in the

Technical reference manual - System parameters

.

contains the configuration files.

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10 Systems

10.4.1. What is saved on backup?

Continued

What is not saved?

A few things are not saved during backup, and it may be vital to be aware of this, in order to save these separately:

•

The environment variable RELEASE: points out the current system pack. System modules loaded with RELEASE: as its path, are not stored in the backup.

• The current value of a PERS object in a installed module is not stored in a backup.

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10 Systems

10.4.2. Backup the system

10.4.2. Backup the system

When do I need this?

ABB recommends performing a backup:

•

before installing new RobotWare.

• before making any major changes to instructions and/or parameters to make it possible to return to the previous setting.

•

after making any major changes to instructions and/or parameters and testing the new settings to retain the new successful setting.

Backup the system

This section describes how to backup the system.

Step

1.

2.

3.

Action

Tap the ABB menu and then tap Backup and Restore.

Tap Backup Current System.

Is the displayed backup path the correct one?

If YES: Tap Backup to perform the backup to the selected directory. A backup file named according to the current date is created.

If NO: Tap ... to the right of the backup path and select directory. Then tap Backup.

A backup folder named according to the current date is created.

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10 Systems

10.4.3. Restore the system

10.4.3. Restore the system

When do I need this?

ABB recommends performing a restore:

• if you suspect that the program file is corrupt.

• if any changes made to the instructions and/or parameters settings did not prove successful, and you want to return to the previous settings.

During the restore, all system parameters are replaced and all modules from the backup directory are loaded.

The Home directory is copied back to the new system’s HOME directory during the warm start.

Restore the system

This section describes how to restore the system.

Step

1.

2.

3.

Action

On the ABB menu, tap Backup and Restore.

Tap Restore System.

Is the displayed backup folder the correct one?

If YES: Tap Restore to perform the restore. The restore is performed, and the system is warm started automatically.

If NO: Tap ... to the right of the backup folder and select directory. Then tap

Restore. The restore is performed, and the system is warm started automatically.

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10 Systems

10.4.4. Important when performing backups!

10.4.4. Important when performing backups!

General

When performing backups or restoring previously made backups, there are several things to keep in mind. Some of these are listed below.

BACKUP directory

A local default backup directory, BACKUP, is automatically created by the system. We recommend using this directory for saving backups! Such backups are not copied to the directory HOME in following backups.

Never change the name of the BACKUP directory.

Also, never change the name of the actual backup to BACKUP, since this would cause interference with this directory.

When is backup possible?

A backup of a system may be performed during program execution. When doing so, a few limitations apply:

•

Start program, load program, load module, close program and erase module can not be done during backup in executing state. The RAPID instructions

Load

and

StartLoad

can, however, be used.

What happens during backup?

Beside the obvious, a backup being made, a few thing happen during backup:

•

Background tasks continue to execute during a backup.

Duplicated modules?

No save operation is performed in the backup command. This implies that two revisions of the same modules can exist in the backup, one from the program memory saved in

Rapid\Task\Progmod\ directory and one from the HOME directory copied to the Backup’s

Home directory.

Large data amount

Too many files in the HOME directory can result in a very large backup directory. The unnecessary files in the Home directory can then be deleted without any problems.

Fault during backup

If a fault occurs during the backup, e.g. full disk or power failure, the whole backup structure is deleted.

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10 Systems

10.5.1. Configuring system parameters

10.5 Configuring systems

10.5.1. Configuring system parameters

About system parameters

System parameters define the system configuration and are defined to order on delivery.

System parameters are edited using the FlexPendant or RobotStudio

Online

.

All system parameters are described in Technical reference manual – System parameters.

Viewing system parameters

This procedure describes how to view system parameter configurations.

Step

1.

2.

Action

On the ABB menu, tap Control Panel.

Tap Configuration.

A list of available types in the selected topic is displayed.

270

3.

4.

5.

en0400001149

Tap Topics to select the topic.

• Controller

• Communication

• I/O

• Man-machine Communication

• Motion

Tap File to save, load, or add new parameters from a file. Select folder and save or load. Proceed to section

Saving, loading system parameter configurations on page 272

.

Tap to select a type and then tap Show Instances. To edit parameters proceed to

section

Editing an instance on page 271

. To add instances proceed to section

Adding a new instance on page 271

.

Continues on next page

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10 Systems

10.5.1. Configuring system parameters

Continued

Editing an instance

This section describes how to edit an instance of a system parameter type.

Step

1.

Action

In the list of system parameter instances, tap to select an instance and then tap

Edit.

The selected instance is displayed.

2.

3.

en0400001151

Tap a parameter name or its value to edit the value.

The way to edit values depend on the data type for the value, e.g. the soft keyboard is displayed for string or numerical values and dropdown menus are displayed for predefined values.

Tap OK.

Adding a new instance

This section describes how to add a new instance of a system parameter type.

Step

1.

2.

3.

Action

In the list of system parameter instances, tap Add.

A new instance with default values is displayed.

Tap the parameter name or its value to edit the value.

Tap OK.

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10 Systems

10.5.1. Configuring system parameters

Continued

Saving, loading system parameter configurations

This section describes how to save and load system parameter configurations, and how to add parameters from a file.

It is recommended to save the parameter configurations before making larger changes to the robot system. The parameters are saved automatically when performing backups.

Step

1.

2.

3.

Action

In the list of types, tap the File menu and tap:

•

Load saved parameters

•

Add new parameters

•

Add or replace parameters

• Save As to save the selected topic’s parameter configurations.

• Save All As to save all topics’ parameter configurations.

Select directory and/or file where you want to save or load the parameters.

Tap OK.

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11 Calibrating

11.1. How to check if the robot needs calibration

11 Calibrating

11.1. How to check if the robot needs calibration

Check robot calibration status

This section describes how to check the robot’s calibration status.

Step

1.

2.

Action

On the ABB menu, tap Calibration.

In the list of mechanical units, check the calibration status.

What kind of calibration is needed?

If the calibration status is...

Not calibrated

Rev. counter update needed

then...

the robot must be calibrated by a qualified service technician. See section

Loading calibration data using the FlexPendant on page 276

.

You must update the revolution counters.

How to update the revolution counters is described in section

Updating revolution counters on page 274

.

No calibration is needed.

Calibrated

DANGER!

Do not attempt to perform the fine calibration procedure without the proper training and tools.

Doing so may result in incorrect positioning that may cause injuries and property damage.

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11 Calibrating

11.2. Updating revolution counters

11.2. Updating revolution counters

Overview

This section details how to perform a rough calibration of each robot axis, i.e. updating the revolution counter value for each axis, using the FlexPendant. Detailed information about revolution counters and how to update them, with calibration positions and scales, can be found in the respective robot’s product manual. Also, see the manuals Instructions for

Levelmeter Calibration and Calibration Pendulum Instruction for information on calibration.

For robots using the Absolute Accuracy option, the calibration data file absacc.cfg must be loaded first.

Storing the revolution counter setting

This procedure details the second step when updating the revolution counter; storing the revolution counter setting.

Step

1.

2.

Action

On the ABB menu, tap Calibration.

All mechanical units connected to the system are shown along with their calibration status.

Tap the mechanical unit in question.

A screen is displayed: tap Rev. Counters.

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3.

en0400000771

Tap Update revolution counters....

A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions:

• Tap Yes to update the revolution counters.

• Tap No to cancel updating the revolution counters.

Tapping Yes displays the axis selection window.

Continues on next page

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11 Calibrating

11.2. Updating revolution counters

Continued

Step

4.

5.

Action

Select the axis to have its revolution counter updated by:

• Ticking in the box to the left

• Tapping Select all to update all axes.

Then tap Update.

A dialog box is displayed, warning that the updating operation cannot be undone:

• Tap Update to proceed with updating the revolution counters.

• Tap Cancel to cancel updating the revolution counters.

Tapping Update updates the selected revolution counters and removes the tick from the list of axes.

6.

-

Caution!

If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury!

Check the calibration position very carefully after each update.

See section

Checking the calibration position

in either of the manuals: Instructions

for Levelmeter Calibration or Calibration Pendulum Instruction, depending on which calibration method to be used. The Product manual for the robot also contains more information about calibration.

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11 Calibrating

11.3. Loading calibration data using the FlexPendant

11.3. Loading calibration data using the FlexPendant

Overview

This section describes how to load calibration data for using the FlexPendant.

The calibration data is delivered on a diskette and will have to be moved to a USB memory or transferred to the controller through FTP.

Load calibration data

This section describes how to load the calibration data.

Step

1.

2.

3.

4.

5.

Action Info

On the ABB menu, tap Calibration and select a mechanical unit. Then tap Calib. parameters.

Tap Load motor calibration....

A dialog box is displayed, warning that loading new calibration offset values may change programmed robot positions:

• Tap Yes to proceed.

• Tap No to cancel.

For systems not running the Absolute Accuracy option the calibration data is normally stored on the serial measurement board (SMB).

Tapping Yes results in displaying a file selection window.

In such case, Update data to controller from SMB memory as detailed in section

Serial

Measurement Board memory on page 280

For system running the Absolute Accuracy option, the calibration data is normally delivered on a diskette.

In such case, proceed below.

Select the file containing the Absolute Accuracy

calibration data to be loaded into the system and tap

OK.

If a file containing invalid calibration data is selected, a dialog box will be displayed. Then re-select a file containing valid calibration data.

Absacc.cfg for systems

with absolute accuracy measurement system

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11 Calibrating

11.4. Editing motor calibration offset

11.4. Editing motor calibration offset

Editing motor calibration offset

This procedure should be used when no specific file with motor calibration data is available, but only the numerical values. These values are normally found on a sticker on the rear of the robot.

Entering motor calibration values may be done in one of three ways:

•

From a disk, using the FlexPendant (as detailed in section

Loading calibration data using the FlexPendant on page 276

).

•

From a disk, using RobotStudio Online (as detailed in section

Loading calibration data

in

Operator’s manual - RobotStudio Online

).

• Manually entering the values, using the FlexPendant (as detailed in section

Editing motor calibration offset on page 277

).

Step

1.

2.

3.

4.

5.

6.

7.

Action Info

On the ABB menu, tap Calibration.

Tap to select mechanical unit and then tap Calibration

Parameters.

Tap Edit motor calibration offset....

A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions:

• Tap Yes to proceed.

• Tap No to cancel.

Tapping Yes results in displaying a file selection view.

Tap the axis to have its motor calibration offset edited.

The offset value box is opened for that particular axis.

Use the numerical keyboard to enter the desired value and then tap OK.

After entering new offset values, a dialog box is displayed, urging you to restart the system to make use of the new values.

Perform a warm restart if required.

After restarting, the contents of the calibration data in the controller cabinet and on the serial measurement board will differ.

Update the calibration data.

Update the revolution counters.

Detailed in section

Serial

Measurement Board memory on page 280

Detailed in section

Updating revolution counters on page 274

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11 Calibrating

11.5. Fine calibration procedure on FlexPendant

11.5. Fine calibration procedure on FlexPendant

Overview

This section describes how to use the FlexPendant when performing a fine calibration of the robot. The method of fitting the calibration equipment to each axis is detailed in the calibration instruction for the axis, see the Product manual for the robot.

Fine calibration procedure

The procedure below details how to perform the fine calibration procedure on the

FlexPendant.

Step

1.

Action

2.

3.

-

Warning!

Do not fine calibrate the robot without special equipment used for axis calibration!

It would cause an unsatisfied accuracy in the robot movement.

On the ABB menu, tap Calibration.

All mechanical units connected to the system are shown along with their calibration status.

Tap to select the mechanical unit.

A screen is displayed: tap Calib. Parameter.

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11 Calibrating

11.5. Fine calibration procedure on FlexPendant

Continued

Step

4.

5.

6.

Action

Tap Fine Calibration....

A dialog box is displayed, urging you to use external equipment to performing the actual calibration. Make sure all necessary calibration equipment is fitted, as detailed in the calibration instruction, for the axis to be calibrated.

A warning that updating the revolution counters may change programmed robot positions is also displayed:

• Tap Yes to proceed.

• Tap No to cancel.

Select the axis to calibrate by ticking the box to the left.

Tap Calibrate.

A dialog box is displayed, warning that calibration of the selected axes will be changed, which cannot be undone:

• Tap Calibrate to proceed.

• Tap Cancel to cancel.

Tapping Calibrate results in briefly displaying a dialog box, announcing that the calibration process has started.

The axis is calibrated and the system returns to the list of available mechanical units.

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11 Calibrating

11.6. Serial Measurement Board memory

11.6. Serial Measurement Board memory

Serial Measurement Board, SMB

The Serial Measurement Board, SMB, primarily gathers resolver data from the robot’s (or additional axes) motors. This data is used to measure the speed and position of each axis.

Each SMB is capable of measuring up to 7 axes. It also stores a number of data pertaining to each robot.

This data is used by the controller and can be transferred between the SMB and the controller.

Normally, the data is transferred automatically, but it can also be done manually.

The SMB data is affected when:

• the robot is replaced

• the SMB is replaced

• the controller (or its flash disk) is replaced.

• updating with new calibration data

The following data is stored on the SMB:

• serial number for the mechanical unit

• joint calibration data

• Absolute Accuracy data

•

SIS data

Note that if the IRC5 controller is to be connected to a robot with an older SMB, not equipped with data storage capability, the SMB needs to be replaced.

SMB data update

If...

then...

the flash disk or the complete controller is new or replaced by an unused spare part...

the data stored in the SMB is automatically copied to the controller memory.

the SMB is replaced by a new, unused, spare part SMB...

the data stored in the controller memory is automatically copied to the SMB memory.

the flash disk or the complete controller is replaced by a spare part, previously used in another system...

the data in the controller memory and the

SMB memory is different. You must update

the controller memory manually from the the SMB memory.

the SMB is replaced by a spare part SMB, previously used in another system...

new calibration data has been loaded via

RobotStudio

Online

or using the FlexPendant and the system has been restarted...

the data in the controller memory and the

SMB memory is different. You must first clear

the data in the new SMB memory, and then

update the SMB memory with the data from the controller memory.

the data in the controller memory and the

SMB memory is different. You must update

the SMB memory manually from the controller memory.

Check that the new calibration values belong to a manipulator with the serial number defined in your system.

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11 Calibrating

11.6. Serial Measurement Board memory

Continued

View SMB data status

This section describes how to view the data status in the Serial Measurement Board and the controller.

Step

1.

2.

Action

On the ABB menu, tap Calibration and select a mechanical unit.

Tap SMB memory and then tap Show status.

The data is displayed with status on the SMB and on the controller.

Update controller data from SMB memory

This section describes how to load data from the Serial Measurement Board to the controller.

Step

1.

2.

3.

4.

Action Info

On the ABB menu, tap Calibration and select a mechanical unit.

Tap SMB memory and then tap Update.

Tap the button Cabinet or manipulator has been

exchanged.

A warning is displayed. Tap Yes to proceed or No to cancel.

It is vital that you load calibration data correctly.

The data is loaded. Tap Yes to acknowledge and restart the robot system.

The following data is updated:

• serial numbers for mechanical units

• calibration data

• Absolute Accuracy data

• SIS data

Update data in SMB memory

This section describes how to update data on the Serial Measurement Board from the controller. This is e.g. after calibration data has been loaded to the controller via RobotStudio

Online or using the FlexPendant.

If the SMB already contains data, you must first clear the memory, see

Delete SMB data on page 282

.

Step

1.

2.

3.

4.

Action Info

On the ABB menu, tap Calibration and select a mechanical unit.

Tap SMB memory and then tap Update.

Tap the button Serial measurement board has

been replaced.

A warning is displayed. Tap Yes to proceed or No to cancel.

It is vital that you load calibration data correctly.

The data is updated.

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11 Calibrating

11.6. Serial Measurement Board memory

Continued

Delete SMB data

This section describes how to delete the data stored on the SMB memory or the controller memory, when creating spare parts.

Step

1.

2.

3.

4.

Action

On the ABB menu, tap Calibration and tap to select a mechanical unit.

Tap SMB memory and then tap Advanced.

The following functions are available:

• Clear Cabinet Memory

• Clear SMB Memory

Tap Clear Cabinet Memory if the controller should be replaced and used as a spare part.

A list of the SMB data stored in the controller is displayed. Tap Clear to delete the memory for the selected robot. Repeat the procedure for all robots in the controller memory.

Tap Clear SMB Memory if the SMB should be replaced and used as a spare part.

A list of the SMB data stored is displayed. Tap Clear to delete the memory for the selected robot. Repeat the procedure for all robots using this SMB board.

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11 Calibrating

11.7. 4 points XZ calibration

11.7. 4 points XZ calibration

Base Frame calibration

This section describes the 4 points XZ calibration, in the Base Frame calibration options.

Other calibration methods may be available in this menu depending on your installed options.

4 points XZ calibration

This section describes how to define the base frame using the 4 points XZ method. This method means that you displace the base frame from the world frame a specified amount in three dimensions and two planes.

xx0400000782

A

X

Y

Z

X’

3HAC 16590-1 Revision: B

Displacement distance between base frame and world frame

X-axis in the base frame

Y-axis in the base frame

Z-axis in the base frame

X-axis in the world frame

Continues on next page

283

11 Calibrating

11.7. 4 points XZ calibration

Continued

Y’

Z’

Y-axis in the world frame

Z-axis in the world frame

Step Action Info

1.

2.

3.

4.

On the ABB menu, tap Calibration and select a mechanical unit. Then tap Base Frame.

Tap 4 points XZ....

Tap ... to change reference point.

A numerical keyboard and boxes for X, Y and Z values are displayed .

Is a file available with all transformation data?

If YES: Tap the Positions menu and then tap Load.

Then select the file containing the values. Load the file.

If NO: Proceed to the next step.

5.

6.

Enter the previously measured displacement in each coordinate box.

Tap OK when done.

You have now specified the amount of displacement the base frame will be moved from the world frame.

Proceed below to specify the direction of the new base frame in relation to the world frame.

Set up a fixed reference position within the working range of the robot, e.g. the tip of a pen secured to the work bench.

7.

8.

Tap Point 1 to highlight the line.

Manually run the robot to the previously fixed reference point.

9.

Tap Modify position.

Modified is displayed on the status line.

10.

Re-orient the robot and again, run it to the reference point but from a different angle.

Repeat these steps until points 1, 2, 3, and 4 have been modified.

11.

Tap Elongator X to highlight the line.

12.

Manually run the robot to a position where the tool center point (TCP) touches an imaginary extension of the X-axis.

The imaginary X-axis is shown in the illustration above.

13.

Tap Modify position.

Modified is displayed on the status line.

14.

To save the entered transformation data to a file, tap the Positions menu and then Save. Enter the name of the file and then tap OK.

15.

To delete all entered transformation data, tap the

Positions menu and then Reset All.

Repeat these steps to modify Elongator Z.

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12 Changing FlexPendant settings

12.1. Changing brightness and contrast

12 Changing FlexPendant settings

12.1. Changing brightness and contrast

Appearance options

This section describes the Appearance menu, where you can adjust the screen’s brightness and contrast.

Changing brightness and contrast

This procedure describes how to change brightness and contrast of the screen.

Step

1.

2.

3.

4.

Action

On the ABB menu, tap Control Panel.

Tap Appearance.

Tap the appropriate Plus or Minus button to adjust the levels. Tap Set Default to return to the default levels.

The brightness and contrast changes as you change the levels which gives you an instant view of how the new levels will affect the visibility.

Tap OK to use the the new brightness and contrast levels.

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12 Changing FlexPendant settings

12.2. Switching between left and right handheld FlexPendant

12.2. Switching between left and right handheld FlexPendant

Left and right handheld

The FlexPendant is set to left handheld on delivery. This can easily be changed to right handheld and back again whenever required.

en0400000913

Switching between left and right handheld

This section details how to switch between right and left handheld FlexPendant.

Step

1.

2.

Action

Tap the ABB menu, then tap Control Panel.

Tap Appearance.

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12 Changing FlexPendant settings

12.2. Switching between left and right handheld FlexPendant

Continued

Step

3.

Action

Tap Rotate right (or Rotate left if the FlexPendant is set for right handheld).

4.

en0400000915

Rotate the FlexPendant and switch to your other arm.

Changes in settings for right handheld FlexPendant

The following settings are effected when changing the FlexPendant to right handheld.

Setting

Jogging directions

Hardware buttons and programmable keys

Hold-to-run button

Enabling device

Effect

The joystick directions are adjusted automatically.

Start, Stop, Forward, and

Backward buttons do not change place with programmable keys.

No effect

No effect

Information

The illustrations of jogging directions in the jogging menu are adjusted automatically for the present left/right mode.

See buttons A-G in the illustration

Hardware buttons on page 39

.

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12 Changing FlexPendant settings

12.3. Changing date and time

12.3. Changing date and time

Changing date and time

This procedure details how to set the controller clock.

Step

1.

2.

3.

4.

Action

On the ABB menu, tap Control Panel.

Tap Date and Time.

The current date and time is displayed.

Tap the appropriate Plus or Minus button to change the date or time.

Tap OK to use the time and date settings.

NOTE!

The date and time is always displayed according to ISO standard, that is, year-month-day and hour:minute, the time using 24-hour format.

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12 Changing FlexPendant settings

12.4. Configuring Most Common I/O

12.4. Configuring Most Common I/O

Most Common I/O

Most Common I/O is used in the Program Editor to display a list of the most commonly used

I/O signals in the robot system. Since there can be many signals, it may be very helpful to be able to make this selection.

The sorting in the list can be rearranged manually. By default, the signals are sorted in the order that they are created.

Most Common I/O can also be configured using system parameters in the topic Man-machine

Communication. However, sorting the list can only be done by using the function under the

Control Panel. See section

Configuring system parameters on page 270

.

Configuring Most Common I/O

This section describes how to configure the list Most Common I/O.

Step

1.

2.

3.

4.

5.

Action

On the ABB menu, tap Control Panel.

Tap I/O.

A list of all I/O signals defined in the system is listed with checkboxes.

Tap the names of the signals to select for the Most Common I/O list.

Tap All or None to select all or no signals.

Tap Name or Type to sort by name or signal type.

Tap Preview to see the list of selected signals and adjust the sort order.

Tap to select a signal and then tap the arrows to move the signal up or down in the list, rearranging the sort order.

Tap APPLY to save the sort order.

Tap Edit to return to the list of all signals.

Tap APPLY to save the settings.

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12 Changing FlexPendant settings

12.5. Changing language

12.5. Changing language

Languages

This procedure details how to change between the currently installed languages. The

FlexPendant supports up to three languages at any one time.

After selecting a specific language, all buttons, menus and dialogs are displayed using this language. RAPID instructions, variables, system parameters, and I/O signals are not affected.

Changing language

This section describes how to change language on the FlexPendant.

Step

1.

2.

3.

4.

Action

On the ABB menu, tap Control Panel.

Tap Language.

A list of all installed languages is displayed.

Tap the language that you want to change to.

Tap OK. A dialog box is displayed. Tap Yes to proceed and restart the

FlexPendant.

The current language is replaced by the selected. All buttons, menus and dialogs are displayed using the new language.

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12 Changing FlexPendant settings

12.6. Editing programmable keys

12.6. Editing programmable keys

Overview

Programmable keys are four hardware buttons on the FlexPendant that may be used for dedicated, specific functions set by the user. See

Hardware buttons on page 39

.

The keys can be programmed to simplify programming or testing of programs. They can also be used to activate menues on the FlexPendant.

Editing programmable keys

This section describes how to edit the programmable keys.

Step

1.

2.

Action

On the ABB menu, tap Control Panel.

Tap ProgKeys.

3.

4.

5.

en0400001154

Select key to edit, Key 1-4 in the upper selection list.

Tap the Type menu to select type of action:

• None

• Input

• Output

• System

If Type Input is selected.

• Tap to select one of the digital inputs from the list.

• Tap the Allow in auto menu to select if the function is also allowed in automatic operating mode.

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291

12 Changing FlexPendant settings

12.6. Editing programmable keys

Continued

Step

6.

7.

8.

9.

Action

If Type Output is selected.

• Tap to select one of the digital outputs from the list

• Tap the Key pressed menu to define how the signal should behave when the key is pressed.

• Tap the Allow in auto menu to select if the function is also allowed in automatic operating mode

Key pressed functions:

• Toggle - switches signal value from 0 to 1 or vice versa

• Set to 1 - sets the signal to 1

• Set to 0 - sets the signal to 0

• Press/Release - sets signal value to 1 while key is pressed (note that an inverted signal will be set to 0)

• Pulse - the signal value pulses once

If Type System is selected.

• Tap the Key pressed menu to select Move PP to main

• Tap the Allow in auto menu to select if the function is also allowed in automatic operating mode

Edit the other keys as described in steps 3 to 7 above.

Tap OK to save the settings.

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12 Changing FlexPendant settings

12.7. Editing supervision settings

12.7. Editing supervision settings

Overview

The motion supervision monitors the robot, and stops the robot if a mechanical drag larger than 300 is detected in the motors. The mechanical drag is a value without any specific unit, with a max value of 300 and a min value of 0.

The motion supervision must be set for each task separately.

Description of functions in RobotWare base:

•

Path Supervision in automatic mode. This is used to prevent mechanical damage due to running into an obstacle during program execution with robot movement.

• Execution Settings. Non motion execution ON is used to run a program without robot motion.

A RobotWare system with the option Collision Detection has additional functionality:

• Path Supervision in manual mode and manual full speed mode.

•

Jog Supervision. This is used to prevent mechanical damage to the robot during jogging.

•

Changing the supervision from a RAPID program.

For more information on Collision Detection, see Application manual - Motion coordination

and supervision.

Editing motion supervision and execution settings

This section describes how to edit the motion supervision and execution settings.

Step

1.

Action

On the ABB menu tap Control Panel and then

Supervision.

Info

2.

en0400000970

Tap the Task menu to select a task for the motion settings.

The settings only apply for one task. If you have more than one task, you need to set the desired values for each task separately.

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293

12 Changing FlexPendant settings

12.7. Editing supervision settings

Continued

Step

3.

4.

5.

Action Info

In the Path Supervision settings, tap ON or OFF to apply or remove path supervision.

Tap the + or - buttons to set the sensitivity.

Note: unless you have the option Collision Detection installed, this only affects the robot in auto mode.

TIP!

The sensitivity may be adjusted from 0 to 300.

Do not set the motion sensitivity lower than 80, or the robot will stop due to internal drag.

In the Jog Supervision settings, tap ON or OFF to apply or remove jog supervision.

Tap the + or - buttons to set the sensitivity.

Note: this only affects the robot if you have the option

Collision Detection installed.

TIP!

The sensitivity may be adjusted from 0 to 300.

Do not set the motion sensitivity lower than 80, or the robot will stop due to internal drag.

Under the Execution Settings, Non motion exectution may be turned ON or OFF.

Non motion execution is described in section Non

motion execution below.

Non motion execution

Non motion execution is a function that enables running a RAPID program without robot motion. All other functions work normally; current cycle times, I/O, TCP speed calculation etc.

This function is mainly used for program debugging, cycle time evaluation, and possibility to measure e.g. glue or paint consumption during a cycle.

Non motion execution is set from the FlexPendant. The function can only be set if the system is in Motors Off state.

When non motion execution is turned on, it can be executed in:

• Manual mode

•

Manual mode full speed

• Auto mode

Cycle times will be simulated according to the selected mode.

WARNING!

Non-motion execution is reset after a reboot. Do not restart the program without checking status of the Non-motion execution. Starting the program incorrectly may cause serious injury or death, or damage the robot or other equipment.

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12 Changing FlexPendant settings

12.8. Configuring view settings

12.8. Configuring view settings

FlexPendant system configurations

The FlexPendant system configuration is used to control views for operating modes and the user authorization system.

View on Operating Mode change

This section describes how to configure the FlexPendant system for which views to show when changing operating mode.

This is used, for example, when a view other than the Production Window is desired when changing to automatic operating mode.

Step

1.

2.

Action

On the ABB menu, tap Control Panel and then tap System.

Tap View on Operating Mode change.

4.

5.

3.

en0400001152

Tap the Operating Mode menu to select:

• View in Auto

• View in Manual

• View in Manual Full Speed

All three modes can be defined.

Tap Edit to define the names for the dll and the instance to create.

The dll can contain a number of instances.

Tap OK.

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12 Changing FlexPendant settings

12.8. Configuring view settings

Continued

User Authorization System protected function visibility

This section describes how to change the visibility of protected functions for the user authorization system, UAS. The protected functions can be hidden or displayed but not accessible. All other administration of the user authorization system is done using

RobotStudio

Online

.

Step

1.

2.

Action

On the ABB menu, tap Control Panel and then tap System.

Tap User Authorization System.

296

3.

4.

en0400001153

Tap to select the level of visibility for User Authorization protected functions:

• Hide non accessible functions

• Show message when accessing protected functions.

Tap OK.

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12 Changing FlexPendant settings

12.9. Changing background image

12.9. Changing background image

Background images

The background image on the FlexPendant can be changed. Any image file on the controller hard disk can be used, a photo as well as an illustration.

For best result, use an image following these recommendations:

• 640 by 390 pixels (width, height)

•

Format gif

Changing background image

This procedure describes how to change background image on FlexPendant.

Step

1.

2.

Action

On the ABB menu, tap Control panel.

Tap System and then Background.

3.

4.

5.

en0500001547

Tap Browse to locate another picture on the controller hard disk.

Tap Default to restore the original background image.

Tap OK to apply the new image or Cancel to leave the background unchanged.

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12 Changing FlexPendant settings

12.10. Calibrating the touch screen

12.10. Calibrating the touch screen

Recalibration

This section describes how to recalibrate the touch screen. The touch screen is calibrated on delivery and normally never needs to be recalibrated.

298 en0400000974

Step

1.

2.

3.

4.

Action

On the ABB menu, tap Control Panel.

Tap Touch Screen.

Tap Recalibrate.

The screen will go blank for a few seconds.

A series of crosses will appear on the screen, one at a time.

Tap the center of each cross with a pointed object.

Info

Caution

Do not use a sharp object which may damage the surface of the screen.

5.

The recalibration is complete.

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13 Descriptions of terms and concepts

13.1. About the Descriptions of terms and concepts chapter

13 Descriptions of terms and concepts

13.1. About the Descriptions of terms and concepts chapter

Overview

This chapter contains descriptions of many of the concepts and words used in this manual.

Note that there may also be additional information in any of the chapters dealing with the feature at hand.

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13 Descriptions of terms and concepts

13.2. What is the robot system?

13.2. What is the robot system?

Description

The concept robot system comprises the manipulator(s), control module, drive module, and all equipment controlled by the controller (tool, sensors, etc.). It includes all hardware as well as software required to operate the robot. Application specific hardware and software, such as spot welding equipment, is not included in the term.

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13 Descriptions of terms and concepts

13.3. What are robots, manipulators and positioners?

13.3. What are robots, manipulators and positioners?

Manipulator

Manipulator is a generic term for mechanical units used to move objects, tools, etc. The term

manipulator includes robot as well as positioner.

Robot

A robot is a mechanical unit with TCP. The term robot does not include the controller.

Positioner

A positioner is a mechanical unit used to move a work object. It may have one or several axes, normally no more than 3 axes. A positioner normally does not have a TCP.

Illustration

The illustration depicts the relation between the concepts robot, manipulator, positioner, mechanical unit, and other units, e.g. external axes.

Mechanical unit

en0400000940

A mechanical unit can be jogged, it can either be a robot, a single additional axis or a set of external axes, for instance a two axis positioner.

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13 Descriptions of terms and concepts

13.4. What is a tool?

13.4. What is a tool?

Tool

A tool is an object that can be mounted directly or indirectly on the robot turning disk or fitted in a fixed position within the robot working range.

A fixture (jig) is not a tool.

All tools must be defined with a TCP (Tool Center Point).

Each tool that may be used by the robot must be measured and its data stored in order to achieve accurate positioning of the tool center point.

Illustration

en0400000803

A

B

Tool side

Robot side

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13 Descriptions of terms and concepts

13.5. What is the tool center point?

13.5. What is the tool center point?

Illustration

The illustration shows how the tool center point (TCP) is the point around which the orientation of the tool/manipulator wrist is being defined.

Description

Moving TCP

Stationary TCP xx0300000604

The tool center point (TCP) is the point in relation to which all robot positioning is defined.

Usually the TCP is defined as relative to a position on the manipulator turning disk.

The TCP will be jogged or moved to the programmed target position. The tool center point also constitutes the origin of the tool coordinate system.

The robot system can handle a number of TCP definitions, but only one may be active at any one time.

There are two basic types of TCPs: moveable or stationary.

The vast majority of all applications deal with moving TCP, i.e. a TCP that moves in space along with the manipulator.

A typical moving TCP may be defined in relation to, e.g. the tip of a arc welding gun, the center of a spot welding gun or the end of a grading tool.

In some applications a stationary TCP is used, e.g. when a stationary spot welding gun is used. In such cases the TCP may be defined in relation to the stationary equipment instead of the moving manipulator.

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13 Descriptions of terms and concepts

13.6. What is a work object?

13.6. What is a work object?

Illustration

Z

X

Y

Z

X

Y

Z

X

Y

Description

en0400000819

A work object is a coordinate system with specific properties attached to it. It is mainly used to simplify programing when editing programs due to displacements of specific tasks, objects processes etc.

The work object coordinate system must be defined in two frames, the user frame (related to the world frame) and the object frame (related to the user frame).

Work objects are often created to simplify jogging along the object’s surfaces. There might be several different work objects created so you must choose which one to use for jogging.

Payloads are important when working with grippers. In order to position and manipulate an object as accurate as possible its weight must be accounted for. You must choose which one to use for jogging.

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13 Descriptions of terms and concepts

13.7. What is a coordinate system?

13.7. What is a coordinate system?

Overview

A coordinate system defines a plane or space by axes from a fixed point called the origin.

Robot targets and positions are located by measurements along the axes of coordinate systems.

A robot uses several coordinate systems, each suitable for specific types of jogging or programming.

•

The base coordinate system is located att the base of the root.It is the easiest one for

just moving the robot from one position to another. See

The base coordinate system on page 305

for more information.

•

The work object coordinate system is related to the work piece and is often the best

one for programming the robot. See

The work object coordinate system on page

307

for more information.

•

The tool coordinate system defines the position of the tool the robot uses when

reaching the programmed targets. See

The tool coordinate system on page 309

for

more information.

•

The world coordinate systemthat defines the robot cell, all other coordiante systems are realted to the the world coordinate system, either directly or indirectly. it is useful for jogging, genral movements and for handling stations and cells with several robots

or robots moved by external axes. See

The world coordinate system on page 306

for

more information.

• The user coordinate system is useful for representing equipment that holds other coordinate systems, like work objects. See

The user coordinate system on page 310

for more information.

The base coordinate system

xx0300000495

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305

13 Descriptions of terms and concepts

13.7. What is a coordinate system?

Continued

The base coordinate system has its zero point in the base of the robot, which makes movements predictable for fixed mounted robots. It is therefore useful for jogging a robot from one position to another. For programming a robot, other coordinate systems, like the work object coordinate system are often better choices. See

The work object coordinate system on page 307

for more information.

When you are standing in front of the robot and jog in the base coordinate system, in a normally configured robot system, pulling the joystick towards you will move the robot along the X axis, while moving the joystick to the sides will move the robot along the Y axis.

Twisting the joystick will move the robot along the Z axis.

The world coordinate system

306 en0300000496

A

B

C

Base coordinate system for robot 1

World coordinate

Base coordinate system for robot 2

The world coordinate system has its zero point on a fixed position in the cell or station. This makes it useful for handling several robots or robots moved by external axes.

By default the world coordinate system coincidences with the base coordinate system.

Continues on next page

3HAC 16590-1 Revision: B

The work object coordinate system

13 Descriptions of terms and concepts

13.7. What is a coordinate system?

Continued

en0300000498

A

B

C

World coordinate system

Work Object coordinate system 1

Work Object coordinate system 2

The work object coordinate system corresponds to the work piece: It defines the placement of the work piece in relation to the world coordinate system (or any other coordinate system).

The work object coordinate system must be defined in two frames, the user frame (related to the world frame) and the object frame (related to the user frame).

A robot can have several work object coordinate systems, either for representing different work pieces or several copies of the same work piece at different locations.

It is in work object coordinate systems you create targets and paths when programming the robot. This gives a lot of advantages:

•

When repositioning the work piece in the station you just change the position of the work object coordinate system and all paths are updated at once.

• Enables work on work pieces moved by external axes or conveyor tracks, since the entire work object with its paths can be moved.

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307

13 Descriptions of terms and concepts

13.7. What is a coordinate system?

Continued

The displacement coordinate system

C

A

D

B en0400001227

C

D

A

B

Original position

Object coordinate system

New position

Displacement coordinate system

Sometimes, the same path is to be performed at several places on the same objec, or on several work pieces located next to each opther. To avoid having to reprogram all positions each time a displacement coordinate system can be defined.

This coordinate system can also be used in conjunction with searches, to compensate for differences in the positions of the individual parts.

The displacement coordinate system is defined based on the object coordinate system.

308

Continues on next page

3HAC 16590-1 Revision: B

The tool coordinate system

13 Descriptions of terms and concepts

13.7. What is a coordinate system?

Continued

xx0300000506

The tool coordinate system has its zero position at the center point of the tool. It thereby defines the position and orientation of the tool. The tool coordinate system is often abbreviated to TCP (Tool Center Point) or TCPF (Tool Center Point Frame).

It is the TCP the robot moves to the programmed positions, when executing programs. This means that if you change the tool (and the tool coordinate system) the robot’s movements will be changed so that the new TCP will reach the target.

All robots have a predefined tool coordinate system, called tool0, located at the wrist of the robot. One or many new tool coordinate systems can then defined as offsets from tool0.

When jogging a robot the tool coordinate system is useful when you don’t want to change the orientation of the tool during the movement, for instance moving a saw blade without bending it.

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309

13 Descriptions of terms and concepts

13.7. What is a coordinate system?

Continued

The user coordinate system

D

A

C

B en0300000497

A

B

C

D

E

User coordinate system

World coordinate system

Work object coordinate system

Moved user coordinate system

Work object coordinate system, moved with user coordinate system

The user coordinate system can be used for representing equipment like fixtures, workbenches. This gives an extra level in the chain of related coordinate systems, which might be useful for handling equipment that hold work objects or other coordinate systems.

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13 Descriptions of terms and concepts

13.8. What is a RAPID application?

13.8. What is a RAPID application?

Purpose

A RAPID application contains a sequence of instructions that controls the robot so that it may perform the operations it is intended for.

Contents of the RAPID application

An application is written using a particular vocabulary and syntax called RAPID

programming language.

The programming language contains instructions in English enabling the robot to move, setting outputs and reading inputs. It also contains instructions for making decisions, to repeat other instructions, to structure the program, to communicate with the system operator and more.

Structure of the RAPID application

The structure of a RAPID application is shown in section

The structure of a RAPID application on page 134

.

How is an application stored?

An application you work with or run must be loaded in the controller’s program memory. This procedure is called to Load the application.

You Save applications on the controller’s hard disk or other disk memory to keep them safe when you want to work on another application.

See also

What is “the memory”? on page 248

.

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13 Descriptions of terms and concepts

13.9. What is a data array?

13.9. What is a data array?

Overview

A data array is a special type of variable: a regular variable may contain one data value, but an array may contain several.

It may be construed as a table, which may have one or more dimensions. This table may be populated with data (e.g. numerical values or character strings) to be used during programming or operation of the robot system.

An example of a three dimensional array is shown below:

312 en0400001006

This array, called "Array" is defined by its three dimensions a, b and c. Dimension a has three rows, b has three rows (columns) and c has two rows. The array and its contents may be written as

Array {a, b, c}

.

Example 1:

Array {2, 1, 1}=29

Example 2:

Array {1, 3, 2}=12

3HAC 16590-1 Revision: B

A

ABB menu

40

Absolute Accuracy data storage

280

additional axes activating

195

deactivating

195

additional axis definition

301

automatic mode about

227

running programs

232

starting in

229

switching to

234

axes illustration

114

selecting

114

B

background changing

297

backup directory

269

important

269

menu

83

system

267

system parameters

272

backward button

39

backward execution about

205

limitations

205

base coordinates definition

116

jogging

116

battery shutdown service routine

211

boot application restart

254

settings

255

using

254

B-start

262

C

calender time counter

213

calibrating

CalPendulum

212

LoadIdentify

214

SMB memory

280

calibration

4 points XZ

283

base frame

283

fine calibration

278

loading data

276

motor calibration offset

277

touch screen

298

calibration menu

84

CalPendulum service routine

212

cfg files

250

characters

Index

entering

97

international

97

close button

40

Configuration files

250

connection

FlexPendant

50

to network

54

connector

38

control module

42

properties

91

control tools, overview

44

controller

42

buttons

47

control module

42

drive module

42

ports

48

properties

91

C-start

259

ctrl.bin file

250

D

data instance

80

,

137

data types changing type

190

creating new

137

editing

139

menu

80

viewing

136

date and time

288

declarations hiding

191

DHCP server

54

drive module

42

buttons

48

options

91

properties

91

Duty timer data

251

E

emergency stop

22

emergency stop button controller

26

,

47

FlexPendant

26

,

38

enabling device

25

,

38

Entry routine

135

error messages

99

ESD damage elimination

20

sensitive equipment

20

wrist strap connection point

20

Ethernet

53

event log menu

87

message

88

explanation, safety symbols

15

expressions editing

188

F

files handling

252

313

Index

programs

165

filtering about

101

data types

101

files

101

programs

101

firmware reflashing

263

Flash disk drive

248

FlexPendant

38

connecting

50

hardware buttons

39

how to hold

41

,

286

main parts

38

reflashing

263

rotating

287

screen

40

FlexPendant Explorer

75

forward button

39

H

Hard disk drive

248

holding brakes

19

hold-to-run button

25

,

38

using

196

HotEdit

73

,

184

positions

73

I

I/O about

76

changing values

238

menu

76

most common

289

safety signals

240

simulating

238

viewing groups

239

I/O, inputs and outputs

237

image.bin file

250

incompatibility hardware/software

263

incremental movement definition

124

quickset

132

setting size

124

size settings

125

,

132

instances data types

137

system parameters

270

instructions backward execution

205

changing motion mode

180

commenting

180

copying and pasting

179

copying arguments

179

cutting

180

data types and declarations

189

editing arguments

177

expressions

188

handling of

176

running from a specific

198

314 undo, redo

176

IP address fixed

55

obtain automatically

54

use no address

54

I-start

261

J

jogging about

105

additional axes

106

axes in independent mode

106

base coordinates

116

coordinated

107

non calibrated mechanical units

106

overview

59

restrictions

106

stationary tool

120

tool coordinates

120

work object coordinates

119

world coordinates

117

world zones

106

jogging menu

77

joystick

38

locking directions

122

joystick directions about

110

illustration

114

locking

122

L

LAN unit

248

languages installed

91

languages, changing

290

left handheld

286

linear motion mode

110

LoadIdentify service routine

214

lock screen

90

login

103

logout, login

103

M

main module

135

main power switch

47

Main routine

135

manipulators definition

301

ManLoadIdentify service routine

218

manual full speed mode about

228

switching to

236

manual mode about

228

running programs

233

starting in

231

switching to

235

mechanical unit quickset

128

Index

selecting

108

,

128

mechanical units activating

195

deactivating

195

definition

301

mechanical units, activating

202

,

204

Memory

249

memory, what is?

248

mirroring

182

mode switch

47

modpos

73

,

184

modules creating

168

deleting

171

handling of

168

loading

169

mirroring

182

renaming

170

saving

169

most common I/O configuring

289

motion mode selecting

110

motion pointer, MP

206

motors on lamp

47

multitasking programs about

222

loading, running and stopping

222

viewing

223

N

network connections properties

91

setting

255

setting up

54

O

operation time counter

213

operator window

40

options installed

91

installed RobotWare

91

P

path returning to

224

path return region

224

payloads creating

161

declarations

161

deleting

164

display definitions

162

editing

162

editing declarations

163

identifying

214

selecting

112

PC, connecting

52

personalizing

72

ports controller

48

positioners definition

301

positions exact

126

format

126

HotEdit

184

modifying

184

moving to

186

tuning

184

power switch

47

,

48

program data menu

80

program directory

165

program execution start button

39

program memory

192

Program module

135

program pointer, PP

206

programmable buttons editing

291

programmable keys editing

291

programs about files

165

creating

165

deleting

192

,

194

handling of

165

loading

166

mirroring

182

multitasking

222

renaming

167

saving

166

starting

219

step by step execution

205

stopping

221

properties control module

91

controller

91

drive module

91

network connections

91

system

91

systems

91

P-start

260

Q

quickset increment

132

mechanical unit

128

run mode

201

speed mode

208

step mode

203

quickset menu

40

R

RAM memory

248

,

249

,

250

RAM memory, illustration

249

RAPID

61

RAPID application

134

RAPID, structure

134

redo instructions

176

reflashing

315

Index

axis computer

263

contactor interface board

263

drive unit

263

firmware

263

FlexPendant

263

panel board

263

profibus

263

reorient motion mode

110

restart

B-start

262

controller

256

C-start

259

I-start

261

menu

92

overview

253

P-start

260

system

256

warm start

257

X-start

258

restore menu

83

system

268

revolution counters battery shutdown

211

setting

274

updating

274

right handheld

286

robots activating

195

deactivating

195

definition

301

robot system

300

RobotWare installed options

91

Routine

135

routines changing declarations

175

copying

175

creating

172

defining parameters

173

deleting

175

handling of

172

mirroring

182

running a specific

200

running service routines

209

run button

39

run mode

201

setting

201

S

safety I/O signals

240

safety stop

23

safety, symbols

15

screen, cleaning

89

scrolling

100

Serial Measurement Board, SMB

280

serial numbers data storage

280

service port

48

,

52

service routines

316 bat_shutdown

211

CalPendulum

212

LoadIdentify

214

ManLoadIdentify

218

running

209

ServiceInfo

213

shut down

69

SIS

251

data storage

280

SIS, Service Information System counters

213

service routine

213

SMB

280

battery shutdown

211

SMB board

250

soft keyboard

97

software options installing

68

speed mode

208

setting

208

start button

39

start up

57

status bar

40

,

95

step by step execution

205

step mode

203

setting

203

stop button

39

supervision settings, editing

293

symbols, safety

15

system backup

267

delete current

259

installing

254

properties

91

restarting

256

restore

268

return to default settings

261

return to stored

262

start and select

258

starting without software

254

System module

135

system parameters configuring

270

instances

270

saving

272

system, starting and selecting

256

system, upgrading

67

systems properties

91

T

targets modifying

73

,

184

moving to

186

tuning

73

,

184

task bar

40

tasks

134

loading program to

223

normal, static, semistatic

222

setting up

222

Index

starting and stopping

222

teach pendant unit

38

tool center point about

142

measuring

148

TCP

142

tool coordinates definition

120

jogging

120

tool frame defining

145

tool orientation setting

113

tool orientation, definition

113

tool, overview control tools

44

tools aligning

187

creating

142

deleting

151

editing declarations

150

editing definitions

149

editing tool data

148

identifying loads

214

make stationary

152

selecting

112

setting up tool coordinate system

153

stationary

152

touch screen

40

background image

297

calibrating

298

TPU

38

trouble shooting

70

tuning

HotEdit

184

positions

184

targets

184

U

UAS configuring views

296

undo instructions

176

USB

252

USB memory

252

USB port

48

V

view settings configuring

295

Viewing messages in programs

94

W

warm start

257

work object coordinates definition

119

jogging

119

work objects creating

154

declarations

154

defining coordinate system

155

deleting

160

editing declarations

159

editing work objects data

158

selecting

112

world coordinates definition

117

jogging

117

write access granting

66

message

99

rejecting

66

X

X-start

258

Z

zooming

100

317

Index

318