ABB IRC5 with FlexPendant Operating Manual

Handling of modules on page 153 .

Lists all modules, see

Lists all routines, see

Handling of routines on page 157

Opens instruction menu, see

Handling of instructions on page 162 .

Opens edit menu, see

Handling of instructions on page 162 .

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

Running a service routine on page 217 , and

About the Program and Motion Pointers on page 167

Functions to search routines and view system data.

• Search Routine : Searches all routines across all the modules (except hidden routines).

• View System Data : Displays all the tasks.

Continues on next page

63 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.2.7

Program Editor

Continued

Modify Position

Hide Declarations

See

Modifying positions in the Program Editor or Production

Window on page 264 .

Hides declarations to make the program code easier to read.

Automatically activate mechanical unit for jogging

If Multitasking is installed with more than one mechanical unit and more than one motion task, then when switching between Program Editor windows the selection of mechanical unit for jogging is not effected. This means when jogging then the last used mechanical unit will move, which not neccessarily is the one used in the active Program Editor .

This setting can be changed with system parameters of the type Automatically

Switch Jog Unit in the topic Man-machine Communication . Turn this setting on to automatically activate the mechanical unit last used in a Program Editor when switching to that window. This means that when jogging, the mechanical unit last used in the active Program Editor moves. Note that when switching between

Program Editors in the same task, there is no change.

Mechanical units are manually activated for jogging in the Jogging window or in the Quickset menu, see

Selecting mechanical unit for jogging on page 132

64 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.2.8

Backup and Restore

3.2.8 Backup and Restore

About backups

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

Backup and restore on page 287

Illustration of Backup and Restore

This is the Backup and Restore menu.

xx0300000440

Backup Current System See

Back up the system on page 287

Restore System See

Restore the system on page 291

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.2.9

Calibration

3.2.9 Calibration

About calibration

The Calibration menu is used to calibrate mechanical units in the robot system.

Calibration can be performed using the option Calibration Pendulum . See Operating manual - Calibration Pendulum .

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

Continues on next page

66 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.2.9

Calibration

Continued

Calibration menu options

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

en0400000771

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.2.10

Control Panel

3.2.10 Control Panel

Control Panel

The Control Panel contains functions for customizing the robot system and the

FlexPendant.

Continues on next page

68 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Illustration Control Panel

3 Navigating and handling FlexPendant

3.2.10

Control Panel

Continued en0400000914

Appearance

Supervision

I/O

Language

ProgKeys

Controller Settings

Touch Screen

FlexPendant

Configuration

Settings to customize the brightness of the display. See

Changing brightness and contrast on page 109 .

Settings for motion supervision and execution settings. See

Using motion supervision and non motion execution on page 247 .

Note

When changing the level of collision detection, it is necessary to bring the motors to off state for activating the changes.

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

Configuring Most Common I/O on page 114 .

Settings for current language for the robot controller. See

Changing language on page 115

Settings for the four programmable keys on the FlexPendant.

See

Changing programmable keys on page 116 .

Settings for configuring the network, the date and time for the robot controller, and the ID of the controller. See

Controller settings on page 112

Recalibration settings for the touch screen. See

Calibrating the touch screen on page 118 .

Configuration of views for operating mode switch and UAS, User

Authorization System. See

Defining a view to be shown during operating mode change or startup on page 101 .

Configuration of the system parameters configuration.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.2.11

Event Log

3.2.11 Event Log

The Event Log

Robot systems are often operated without any personnel present. The logging function is a way to store information about past events for future reference in order to facilitate troubleshooting.

How to open the event log is described in

Accessing the event log on page 283 .

Illustration Event Log

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

xx0300000447

Function

View a message

Description

Tap the message. The message structure is described in

An event log message on page 71 .

Scroll or zoom a message See

Scrolling and zooming on page 92

Delete the log See

Deleting log entries on page 284 .

Save the log

Close the log

See

Saving log entries on page 285 .

See

Accessing the event log on page 283 .

Continues on next page

70 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.2.11

Event Log

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

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

Operating manual - Troubleshooting IRC5 .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.2.12

System Info

3.2.12 System Info

About System Info

System Info displays information about the controller and the loaded system. Here you can find the RobotWare version and options currently in use, current keys for control and drive modules, network connections, and so on.

Illustration of System Info view en0400000968

Controller properties

It contains controller and network information. When the Controller properties is expanded the following are visible:

Network connections

Installed systems

Service port and Local Area Network properties.

List of installed systems.

System properties

It contains information of the system that is currently in use. When the System properties is expanded the following are visible:

Control module

Options

Drive modules

Drive module x

Options

Additional options

Name and key of the Control Module.

Installed RobotWare options and languages.

Lists all Drive Modules.

Name and key of Drive Module x.

Drive Module x options, with type of robot and so on.

Any RobotWare options and Process application options.

Continues on next page

72 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.2.12

System Info

Continued

Hardware devices

It contains information of all the hardware attached. When the Hardware devices is expanded the following are visible:

Controller

Computer system

Power supply system

Panel board

Drive module x

Mechanical units

Name and key of the Control Module.

Contains information of the main computer.

Contains information of the Power supply unit.

Provides information about the panel board hardware and software.

It contains information about the axis computer, drive unit, and contactor board.

Lists the data of Robots or external axes connected to the controller.

Software resources

It contains information about the RAPID. When the Software resources is expanded the following are visible:

System

RAPID

RAPID memory

RAPID performance

Communication

Contains information about system uptime and memory.

Software used by the controller.

Memory allocated for RAPID programs.

Shows the execution load.

Contains information about Remote Service Embedded.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.2.13

Restart

3.2.13 Restart

Restart

A running system normally does not need to be restarted.

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

en0500001557

74 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.2.14

Log Off

3.2.14 Log Off

The Log Off menu

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

Logging on and off on page 98

Log Off is available under the ABB menu.

en0400000947

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.3 Operator window

3.3 Operator window

Operator window

The operator window displays messages from the program. With Multitasking installed, all tasks’ 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: en0400000975

Clear Clears all messages

Don’t Show Logs Clears all messages

Don’t Show Task Name Hides task names

76 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.4 Status bar

3.4 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

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.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.5.1 The Quickset menu

3.5 Quickset

3.5.1 The Quickset menu

Quickset menu

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

Each button on the menu shows the currently selected property value or setting.

In manual mode, the Quickset menu button shows the currently selected mechanical unit, motion mode, and increment size.

Illustration of the Quickset menu

This section describes the buttons in the Quickset menu.

78 en0300000471

Mechanical unit, see

Quickset menu, Mechanical unit on page 79

Increment, see

Quickset menu, Increment on page 84

Run Mode, see

Quickset menu, Run Mode on page 85 .

Step Mode, see

Quickset menu, Step Mode on page 86

Speed, see

Quickset menu, Speed on page 87 .

Tasks, see

Quickset menu, Tasks on page 88

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.5.2 Quickset menu, Mechanical unit

Illustration Mechanical unit button

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

en0300000539

Mechanical unit menu button

Mechanical unit, a selected unit is highlighted. See

Selecting mechanical unit for jogging on page 132

Motion mode settings (axes 1-3 motion mode currently selected), further settings are described in

Illustration Motion mode settings on page 80

Tool settings (tool 0 currently selected), further settings are described in

Illustration Tool settings on page 81

Work object settings (work object 0 currently selected), further settings are described in

Illustration Work object settings on page 81 .

Coordinate system settings (world coordinate currently selected), further settings are described in

Illustration Coordinate system settings on page 82

Turn coordination off , further settings are described in

Turn coordination off on page 83 .

Show details , further settings are described in

Illustration Show Details on page 83 .

Note

The Mechanical unit menu is only available in manual mode.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

3 Navigating and handling FlexPendant

3.5.2 Quickset menu, Mechanical unit

Continued

Illustration Motion mode settings

To view or change any motion mode functionality, tap the Motion mode settings button. These settings are also available in the Jogging window, see

Selecting motion mode on page 134 .

en0300000540

Select motion mode setting:

• Axis 1-3

• Axis 4-6

• Linear

• Reorient

Continues on next page

80 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.5.2 Quickset menu, Mechanical unit

Continued

Illustration Tool settings

To view or change the available tools, tap the Tool settings button. These settings are also available in the Jogging window, see

Selecting tool, work object, and payload on page 135 .

en0400000988

Illustration Work object settings

To view or change the available work objects, tap the Work object settings button.

These settings are also available in the Jogging window, see

Selecting tool, work object, and payload on page 135

en0400000989

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

3 Navigating and handling FlexPendant

3.5.2 Quickset menu, Mechanical unit

Continued

Select a work object to use.

Illustration Coordinate system settings

To view or change coordinate system functionality, tap the Coordinate system settings button. These settings are also available in the Jogging window, see

Selecting coordinate system on page 138 .

en0300000541

Select a coordinate system setting:

• World coordinate system

• Base coordinate system

• Tool coordinate system

• Work object coordinate system

Continues on next page

82 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.5.2 Quickset menu, Mechanical unit

Continued

Illustration Show Details

Tap Show Details to display the settings available for a mechanical unit.

en0500002354

Override jog speed settings (100% currently selected)

Coordinate system settings

Motion mode settings

Turn on or off user increment

Turn on or off jog supervision

If any of the settings are not available, they will crossed over.

Motion mode and coordinate settings can be changed by tapping the buttons.

Tap Hide Details to return to the basic display.

Turn coordination off

To quickly change between coordinated and uncoordinated jogging, use the coordination off button.

The button is automatically hidden when you change anything that effects coordination, for example the work object or the coordinate system of the coordinated mechanical unit.

To re-enable the button you must setup coordination again manually.

For information about coordination between MultiMove robots, see Application manual - MultiMove .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.5.3 Quickset menu, Increment

Increment settings

The increment settings are also available in the Jogging window. For more details, see

Incremental movement for precise positioning on page 141

Illustration Increment

84 en0300000542

None

Small

Medium

Large

User

Show/Hide Values

Angle unit

No increments

Small movements

Medium movement

Large movements

User defined movements

Displays/hides increment values

Defines the unit for the angles.

Note

The Increment menu is available only in manual mode.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.5.4 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.

For information about run mode in:

• Multitasking , see Application manual - Controller software IRC5 , section

Multitasking .

• MultiMove , see Application manual - MultiMove , section User interface specific for Multimove .

Illustration Run mode en0300000472

Single Cycle

Continuous

Runs one cycle then stops execution.

Runs continuously.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.5.5 Quickset menu, Step Mode

Step mode

By setting the step mode you can define how the step-by-step program execution should function. For more details, see

Stepping instruction by instruction on page 214

Illustration Step mode

86 en0300000543

Step Into

Step Out

Step Over

Next Move

Steps into called routines and executes them step-by-step.

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.

Called routines are executed in one single step.

Steps to the next move instruction. Stops before and after movement instructions, for example, to modify positions.

Note

If you select the Step Out / Step Over / Next Move step modes, an arrow icon

( ) is also displayed in the QuickSet menu indicating that the selected mode is not a Step Into step mode.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.5.6 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.

Illustration Speed

Tap the Speed button to view or change the speed settings. The current running speed, in relation to max, is displayed above the buttons.

en0300000470

-1%

+1%

-5%

+5%

25%

50%

100%

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%

Set speed to 0%

Run at quarter speed (25%)

Run at half speed (50%)

Run at full speed (100%)

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.5.7 Quickset menu, Tasks

Tasks button

If you have the option Multitasking installed there can be more than one task.

Otherwise there is only one task.

By default, you can activate/deactivate only Normal tasks from the Quickset menu.

However, from the Control Panel , you can change the settings so that All tasks can be activated/deactivated.

Activated tasks are started and stopped with the Start and Stop buttons on the

FlexPendant.

The tasks settings are only valid for manual operating mode.

Related information

Application manual - Controller software IRC5 , section Multitasking .

How to start and stop multitasking programs is described in section

Using multitasking programs on page 245

TrustLevel for tasks are set with system parameters, see section Task in Technical reference manual - System parameters .

You can define if all tasks or only normal tasks should be displayed. See section

Defining which tasks should be selectable in the tasks panel on page 107 .

88 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.6.1 Using the soft keyboard

3.6 Basic procedures

3.6.1 Using the soft keyboard

Soft keyboard

The soft keyboard is used frequently when operating the system, for example 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.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

3 Navigating and handling FlexPendant

3.6.1 Using the soft keyboard

Continued

Changing the insertion point

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

If you need to move...

backward then tap...

xx0300000492 forward xx0300000493

Deleting

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

xx0300000494

90 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.6.2 Messages on the FlexPendant

3.6.2 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 283

. All messages are also described in Operating manual - Troubleshooting 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.

To be able to change configurations and settings in the system from RobotStudio, 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 is described in Operating manual - RobotStudio .

Program messages

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

Operator window on page 76 .

How to generate program messages is described in Technical reference manual - RAPID Instructions, Functions and Data types .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.6.3 Scrolling and zooming

3.6.3 Scrolling and zooming

Overview

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

• Scroll up/down (and sometimes left/right)

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

92 en0400000685

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 )

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.6.4 Filtering data

3.6.4 Filtering data

Filtering data

In several of the FlexPendant menus you can use filtering. This can be useful when you are looking at instances of a data type, for example, and there are more available than is possible to overlook. By filtering instances starting with a specific character for example, the number can be greatly reduced.

Depending on the type of data, you can filter data either alphabetically or numerically.

Illustration of filtering

The filter function is switched on until the active filter is removed (For example, by tapping Reset ).

en0500001539

Note

When filtering I/O signals there are more options than for many other types of data. For example,

• you can filter data by Name or Category .

• filtering function can be displayed automatically if the number of signals displayed exceeds a predefined number. See

Illustration of automatic filter display on page 95

Continues on next page

93 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.6.4 Filtering data

Continued en1200000669

Figure 3.1:

Active filter

Clear

Reset

123 / ABC

Filter en1100000506

Displays the current filter. It is also displayed at the top of the list of items.

Clears the text within the Active filter text box.

Removes the filter string.

Depending on type of data, there may be one or several ways to filter data, e.g. numeric, alphabetic.

Applies the filter.

Opens and closes the Active filter menu.

Continues on next page

94 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.6.4 Filtering data

Continued

Illustration of automatic filter display

The I/O signal filter can be set to be displayed automatically if the number of data exceeds a predefined number.

en0600002643

Action

Tap Change to edit the setting controlling when the filter dialog should appear.

Enter a new number defining the upper limit for not using the filter. Then tap

Done .

Tap Virtuals to select if all, or only virtual, or only non virtual signals should be listed.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.6.5 Process applications

3.6.5 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 views.

Start a process application

Use this procedure to start a process application.

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.

96 en0400000768

The views and process application running in this case are:

FlexPendant Explorer view

Program Editor view

RobotWare Arc, a process application

Control Panel view

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.6.6 Granting access for RobotStudio

3.6.6 Granting access for RobotStudio

About write access on the controller

The controller accepts only one user with write access at a time. Users in

RobotStudio can request write access to the system. If the system is running in manual mode, the request is accepted or rejected on the FlexPendant.

Granting access for RobotStudio

This procedure describes how to grant access for RobotStudio.

Action

When a user in RobotStudio 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 Deny .

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

Note

For a system connected to T10, users in RobotStudio can request write access by pressing the enabling device twice and logging in as a local client.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.6.7 Logging on and off

3.6.7 Logging on and off

Logout procedure

Use this procedure to log off the system.

Action

On the ABB menu, tap Log Off .

Tap Yes to confirm.

Login procedure

Use this procedure to log on to the controller, using the User Authorization System,

UAS. UAS can limit the available functions for users.

After a log off, the Login window is displayed automatically.

en0400000947

Action

Tap on the User menu and select a user.

If there are more than seven users then the menu is replaced with a button.

Information

If you select Default User , then no password is required, and you are logged on 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.

Enter the password and tap OK .

Tap Login .

Continues on next page

98 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.6.7 Logging on and off

Continued

Handling users and authorization levels

Read more on how to add users or set the authorization in Operating manual - RobotStudio .

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

Defining a view to be shown during operating mode change or startup on page 101 .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.7.1.1 Setting default paths

3.7 Changing FlexPendant settings

3.7.1 System settings

3.7.1.1 Setting default paths

Introduction to default paths

You can set individual default paths for some actions using the FlexPendant.

The following default paths can be set:

• Saving and loading RAPID programs.

• Saving and loading RAPID modules.

• Saving and storing configuration files.

This function is available if the user that is logged on is authorized. User authorization is handled via RobotStudio. See Operating manual - RobotStudio .

Setting default paths

Use this procedure to set a default path.

Action

On the ABB menu, tap Control Panel and then FlexPendant .

Tap File System Default Path .

100 en0500002361

Tap the File type menu to choose type of default path:

• RAPID programs

• RAPID modules

• Configurations files

Type the default path or tap Browse , to choose the desired location.

If required, any previously entered path can be removed by tapping Clear .

Tap OK .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.7.1.2 Defining a view to be shown during operating mode change or startup

3.7.1.2 Defining a view to be shown during operating mode change or startup

View on operating mode change or startup

This function can be used, for example, if a view other than the Production Window is desired when switching to Auto mode.

Defining view on operating mode change

Use the following procedure to configure the FlexPendant to automatically show a specified view during a change in operating mode or during startup.

Action

On the ABB menu, tap Control Panel and then tap FlexPendant .

Tap View on System Event .

The View on System Event window is displayed.

en0400001152

Tap the System Event list and select a type of system event.

Following are the available types:

• Switching to Auto : Select this option to define the FlexPendant view when switching to auto mode.

• Switching to Manual : Select this option to define the FlexPendant view when switching to manual mode.

• Switching to Manual Full Speed : Select this option to define the FlexPendant view when switching to manual full speed mode.

• FlexPendant Startup : Select this option to define the view when the FlexPendant starts.

In the Selected view field, tap ...

and select a desired application to be displayed during the selected system event.

Tap OK .

The changes are saved.

Note

The Clear View button will remove the currently selected view if you do not want any view to be automatically shown.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

101

3 Navigating and handling FlexPendant

3.7.1.3 Changing the background image

3.7.1.3 Changing the 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

Use this procedure to change background image on FlexPendant.

Action

On the ABB menu, tap Control panel .

Tap FlexPendant and then Background Image .

en0500001547

Tap Browse to locate another picture on the controller hard disk.

Tap Default to restore the original background image.

Tap OK .

102 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.7.1.4 Defining visibility level for UAS protected functions

3.7.1.4 Defining visibility level for UAS protected functions

Introduction to visibility levels

This section describes how to define visibility level for functions protected by 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. See Operating manual - RobotStudio .

Defining visibility level for UAS protected functions

Action

On the ABB menu, tap Control Panel and then tap FlexPendant .

Tap User Authorization System .

en0400001153

Tap to select the level of visibility for UAS protected functions:

• Hide non accessible functions OR

• Show message when trying to access protected functions.

Tap OK .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

103

3 Navigating and handling FlexPendant

3.7.1.5 Defining an additional test view

3.7.1.5 Defining an additional test view

Overview

If your system has a customized operator interface, that is one or several applications developed with FlexPendant SDK, it is possible to enable the user to start program execution in manual mode from such an application. If there is no such application, however, the screen for adding other test views will look as in the illustration below.

Defining an additional test view

Use this procedure to define an additional test view.

Action

On the ABB menu, tap Control Panel and then FlexPendant .

Tap Additional Test View .

The displayed screen might look like this: en0600003110

Usually only the Program Editor and the Production Window are allowed test views.

In case there are additional views to choose from, these will appear in the list. Check one or several applications to be used as additional test views.

Tap OK .

104 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.7.1.6 Defining position programming rule

3.7.1.6 Defining position programming rule

Introduction to position naming

Robot positions in a RAPID program are either named variables or not named

(using the asterisk character, *). The programmer can choose which naming rule the FlexPendant should use when new move instructions are programmed.

Defining position programming rule

Use this procedure to define a naming rule for new robot positions.

Action

On the ABB menu, tap Control Panel and then FlexPendant .

Tap Position Programming Rule .

en0500002415

Tap to select the preferred position programming rule.

Tap OK .

Position programming rules

This section gives a detailed description of the options available when programming robot positions, here referred to as targets . This signifies the position to which the mechanical unit is programmed to move.

New targets can be named according to any of these principles:

• New position created; * or sequential naming rule.

• Next sequential already existing position selected.

• No new position created; * naming rule.

New position created; * or sequential naming rule

This is the default setting. When a move instruction is programmed, a new target will automatically be created. If the last target was named, that is not using an “*”, the new target will be named in sequence with the previous one.

Continues on next page

105 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.7.1.6 Defining position programming rule

Continued

For example:

MoveJ p10 will be followed by

MoveJ p20

, unless this target already exists in the program. In such a case, MoveJ p30 (or the next free number) will be used instead.

Next sequential already existing position selected

When a move instruction is programmed, no new target will be created. Instead, the next target in a sequence created beforehand will be selected. The very first target, however, will be an “*”, as no sequence yet exists. As soon as the first target has been defined this rule will be applied.

For example: A number of targets have been predefined; p10 to p50. In such a case,

MoveJ p10 will be followed by

MoveJ p20

. The next instruction will use target p30, etc. until p50 is reached. Since no further targets have been defined, p50 will be used for the following targets as well.

No new position created; * naming rule

When a Move instruction is programmed, no new target will be created. Instead, an “*” will always be used. This can be replaced by an existing target at a later stage.

For example: MoveJ p10 will be followed by MoveJ * .

106 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.7.1.7 Defining which tasks should be selectable in the tasks panel

3.7.1.7 Defining which tasks should be selectable in the tasks panel

Tasks panel

The tasks panel is found in the Quickset menu. See

Quickset menu, Tasks on page 88 .

Tip

To simplify debugging of background tasks you can make all tasks (including the background tasks) visible in the task panel on the FlexPendant. Then, in manual mode, all tasks that are selected in the task panel (including background tasks) will stop when pressing the stop button.

Defining which tasks to show

Use this procedure to define which tasks should be selectable in the tasks panel in the Quickset menu.

Action

On the ABB menu, tap Control Panel and then tap FlexPendant .

Tap Task Panel Settings .

Select Only Normal tasks or All tasks .

When All tasks is selected, then all tasks that are selected in the task panel (including background tasks) will stop when pressing the stop button. The selected background tasks will be treated as if the value of the system parameter Trustlevel is defined as

NoSafety .

Tap OK .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

107

3 Navigating and handling FlexPendant

3.7.1.8 Managing the display of controller and system name

3.7.1.8 Managing the display of controller and system name

Overview

You can manage the display of controller and system name using this feature.

Controller and System name

Use the following procedure to manage the display of controller and system name in the status bar.

Action

On the ABB menu, tap Control Panel and then tap FlexPendant .

The FlexPendant Configuration Properties window is displayed.

Navigate and tap Controller and System Name .

The Controller and System Name window is displayed.

108 xx1700000330

Select a controller and system naming option according to your requirement.

Following are the available options and its description:

• Controller name only. (Default) : Displays only the name of the controller in the status bar. This is the default option.

• System name only : Displays only the name of the system in the status bar.

• Both Controller and System name : Displays both the controller and system name in the status bar.

Tap OK .

The changes are applied and displayed in the status bar.

Tap Close .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.7.2.1 Changing brightness and contrast

3.7.2 Basic settings

3.7.2.1 Changing brightness and contrast

Appearance options

This section describes the Appearance menu, where you can adjust the screen’s brightness and contrast. The contrast can only be adjusted on FlexPendant without

USB port.

Changing brightness and contrast

Use this procedure to change brightness and contrast of the screen.

Action

On the ABB menu, tap Control Panel .

Tap Appearance .

Tap the Plus or Minus button to adjust the levels. Tap Set Default to return to default.

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 new brightness and contrast levels.

Note

If you change brightness or contrast from the default levels, some screens can appear to be striped. This is however not a sign of a faulty screen. Change back to default settings to avoid the striped appearance.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

109

3 Navigating and handling FlexPendant

3.7.2.2 Adapting the FlexPendant for left-handed users

3.7.2.2 Adapting the FlexPendant for left-handed users

Overview

The device is usually operated while being supported by the left hand. A left-hander, however, normally prefers to use his left hand for using the touch screen. however, can easily rotate the display through 180 degrees and use his right hand to support the device. The FlexPendant is set to suit right-handers on delivery, but can easily be adapted to suit the needs of the left-handed.

Illustration

The FlexPendant operated by a right-handed person at the top and by a left-handed person at the bottom. Especially note the location of the emergency button when the display is rotated through 180 degrees.

en0400000913

Rotating the FlexPendant screen

Use this procedure to adapt the FlexPendant to suit a left-handed user.

Action

Tap the ABB menu, then tap Control Panel .

Tap Appearance .

Continues on next page

110 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Action

Tap Rotate right .

3 Navigating and handling FlexPendant

3.7.2.2 Adapting the FlexPendant for left-handed users

Continued en0400000915

4 Rotate the FlexPendant and move it to the other hand.

What is affected?

The following settings are affected when adapting the FlexPendant for a left- handed user.

Setting

Jogging directions

Hardware buttons and programmable keys

Emergency stop

Three-position enabling device

Effect

The joystick directions are adjusted automatically.

Information

The illustrations of jogging directions in the jogging menu are adjusted automatically.

See buttons A-G in the illustration

Hard buttons on page 39 .

Start , Stop , Forward , and

Backward buttons do not change place with programmable keys.

No effect.

Differently located, at the bottom instead of at the top.

No effect

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

111

3 Navigating and handling FlexPendant

3.7.2.3 Controller settings

3.7.2.3 Controller settings

Date and time settings

Use the following procedure to configure date and time.

Step

Action

On the ABB menu, tap Control Panel .

Tap Controller Settings .

The Date and Time settings window is displayed.

In the Settings section, select Network Time or Manual Time .

Select Network Time for configuring the robot controller for automatic time synchronization using NTP protocol of a time server. The time server is identified by its IP address or DNS name. Select Manual Time if you do not have a time server that is reachable from the controller.

Select the required time zone from the Time Zone section.

In the Date and Time section, tap the + (Plus) or (Minus) button and configure the date and time.

Tap OK .

The selected settings are saved.

Note

The date and time are displayed according to the ISO standard. That is, date is in the year-month-day format and time is in the hour:minute format (24-hour format).

Network settings

Use the following procedure to configure the network.

Step

Action

On the ABB menu, tap Control Panel .

Tap Controller Settings .

Navigate to the bottom menu, tap Settings , and select Network .

The Control Panel - Controller Settings - Network window is displayed.

Configure the network settings according to your requirements.

Tap OK .

The selected settings are saved.

Identity settings

Use the following procedure to configure the identity of the controller.

Step

Action

On the ABB menu, tap Control Panel .

Tap Controller Settings .

Navigate to the bottom menu, tap Settings , and select Identity .

The Control Panel - Controller Settings - Identity window is displayed.

Edit the name of the controller in the Controller Name field according to your requirement.

Continues on next page

112 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.7.2.3 Controller settings

Continued

Step

Action

Tap OK .

The name of the controller is saved.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

113

3 Navigating and handling FlexPendant

3.7.2.4 Configuring Most Common I/O

3.7.2.4 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 can be helpful to use 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.

Configuring Most Common I/O

Use this procedure to configure the list Most Common I/O.

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 check boxes.

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.

114 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.7.2.5 Changing language

3.7.2.5 Changing language

Languages

The FlexPendant is installed with and supports twenty different languages. By default, the current language is English.

Switching from one installed languages to another is easy. For more information, see

Changing language on page 115 .

Note

When you switch to another language, all buttons, menus and dialogs will use the new language. RAPID instructions, variables, system parameters, and I/O signals are not affected.

Changing language

Use this procedure to change language on the FlexPendant.

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 one.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

115

3 Navigating and handling FlexPendant

3.7.2.6 Changing programmable keys

3.7.2.6 Changing programmable keys

Overview

Programmable keys are four hardware buttons on the FlexPendant that can be used for dedicated, specific functions set by the user. See

Hard buttons on page 39 .

The keys can be programmed to simplify programming or testing of programs.

They can also be used to activate menus on the FlexPendant.

Change programmable keys

Use the following procedure to set the programmable keys:

Action

On the ABB menu, tap Control Panel .

Tap ProgKeys .

en0400001154

Select key to set, 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.

Note

An input cannot be set by using the programmable keys, its value can only be pulsed.

The pulse will be the inverted value of the input.

Continues on next page

116 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.7.2.6 Changing programmable keys

Continued

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

Set the other keys as described in steps 3 to 7 above.

Tap OK to save the settings.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

117

3 Navigating and handling FlexPendant

3.7.2.7 Calibrating the touch screen

3.7.2.7 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. Depending on

FlexPendant model, the appearance of the symbols will vary, the function is however the same.

en0400000974

Calibrating the touch screen

Use this procedure to calibrate the touch screen.

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 symbols will appear on the screen, one at a time.

Tap the center of each symbol with a pointed object.

Information

CAUTION

Do not use a sharp object which can damage the surface of the screen.

5 The recalibration is complete.

About the touch calibration function

The touch calibration function waits on each calibration point for a couple of touch coordinates or that the touch will be released. Then the average of the collected coordinates will be calculated and the symbol moves to the next position.

Continues on next page

118 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

3 Navigating and handling FlexPendant

3.7.2.7 Calibrating the touch screen

Continued

The touch controller only sends new coordinates to the CPU when the coordinates are changing. If you touch the symbol very accurately with a stylus, the touch coordinates will not change. Then the touch controller sends only one coordinate and the touch calibration function is waiting endlessly for more coordinates.

The best way to avoid this problem is to tap the symbol for only one second and then release.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

119

This page is intentionally left blank

4 Jogging

4.1 Introduction to jogging

4 Jogging

4.1 Introduction to jogging

What is jogging?

To jog is to manually position or move robots or external axes.

When can I jog?

You can jog in manual mode but you cannot jog during program execution.

Jogging the robot

This procedure details the main steps for jogging the robot.

Action Information

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 three-position 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 29

Starting in the Manual mode is detailed in section

Starting programs on page 241 .

How to switch to manual mode is detailed in section

Switching from automatic to manual mode on page 261 .

Determine in which way you want to jog.

The difference between different types of jogging is detailed in section

Introduction to jogging on page 121 .

How to select coordinate system is detailed in section

Selecting coordinate system on page 138 .

Select a mechanical unit. The axes can be jogged in different ways.

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

Jog axis by axis on page 137

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 Technical reference manual - System parameters .

Jog the manipulator using the joystick on the FlexPendant.

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

The

FlexPendant on page 37 .

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

Selecting motion mode on page 134 .

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

Locking the joystick in specific directions on page 139 .

There might be restrictions to how you can jog, see section

Restrictions to jogging on page 130 .

In some cases, more than one manipulator can be jogged simultaneously. This requires the option MultiMove .

How to jog multiple manipulators is detailed in section

Coordinated jogging on page 131 .

Continues on next page

121 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

4 Jogging

4.1 Introduction to jogging

Continued

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

Coordinate systems for jogging on page 123 .

122 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

4 Jogging

4.2 Coordinate systems for jogging

4.2 Coordinate systems for jogging

Coordinate systems

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 at the base of the robot. It is the easiest one for just moving the robot from one position to another.

• The work object coordinate system is related to the work piece and is often the best one for programming the robot.

• The tool coordinate system defines the position of the tool the robot uses when reaching the programmed targets.

• The world coordinate system that defines the robot cell, all other coordinate systems are related to the world coordinate system, either directly or indirectly. It is useful for jogging, general movements and for handling stations and cells with several robots or robots moved by external axes.

• The user coordinate system is useful for representing equipment that holds other coordinate systems, like work objects.

Default settings

If you change coordinate system in the jogging properties, this will automatically be reset to default settings after a restart.

Linear mode

For each mechanical unit the system will by default use the base coordinate system for the linear motion mode.

Reorient mode

For each mechanical unit the system will by default use the tool coordinate system for the reorientation motion mode.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

123

4 Jogging

4.2 Coordinate systems for jogging

Continued

Illustration of axes and joystick directions

The axes of a generic six axis manipulator can be jogged manually using the joystick. Please check your plant or cell documentation to determine the physical orientation of any additional axes.

The illustration shows the movement patterns for each manipulator axis.

xx0300000520

Continues on next page

124 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

The base coordinate system

4 Jogging

4.2 Coordinate systems for jogging

Continued xx0300000495

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 126

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.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

125

4 Jogging

4.2 Coordinate systems for jogging

Continued

The work object coordinate system

Examples of use xx0600002738

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.

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.

Continues on next page

126 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

The tool coordinate system

4 Jogging

4.2 Coordinate systems for jogging

Continued

Examples of use en0300000497

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 TCPF (Tool Center Point Frame) and the center of the tool coordinate system is abbreviated TCP (Tool Center Point).

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.

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

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

127

4 Jogging

4.2 Coordinate systems for jogging

Continued

The world coordinate system

Examples of use en0300000496

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 coincides with the base coordinate system.

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.

128 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

4 Jogging

4.3 Joystick directions

4.3 Joystick directions

Introduction to joystick directions

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.

Joystick directions

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

Motion mode

Linear

Illustration joystick Description

Linear mode is described in section

Setting the tool orientation on page 136

Axis 1, 2, and 3

(default for robots) en0400001131

Axis 1-3 mode is described in section

Jog axis by axis on page 137

en0300000536

Axis 4, 5, and 6 Axis 4-6 mode is described in section

Jog axis by axis on page 137

en0300000537

Reorient Reorient mode is described in section

Setting the tool orientation on page 136 .

en0400001131

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

129

4 Jogging

4.4 Restrictions to jogging

4.4 Restrictions to jogging

Jog additional axes

Additional axes can only be jogged axis-by-axis. Please see Application manual - Additional axes and stand alone controller .

Jog mechanical units that are not calibrated

If the mechanical unit is not calibrated the text Unit not calibrated will be displayed in the Position area of the Jogging window.

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

When the robot is not calibrated, incremental movement is restricted to one step per joystick deflection. A calibrated robot performs 10 steps/sec when deflecting the joystick.

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 - Controller software

IRC5 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 - Controller software IRC5 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.

130 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

4 Jogging

4.5 Coordinated jogging

4.5 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

Action

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

Set Coordinate system to Work Object.

Information

See

Selecting mechanical unit for jogging on page 132

See

Selecting coordinate system on page 138 .

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

See

Selecting tool, work object, and payload on page 135 .

Select the mechanical unit that moves the work object.

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 . See Application manual - MultiMove .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

131

4 Jogging

4.6.1 Selecting mechanical unit for jogging

4.6 Basic settings for jogging

4.6.1 Selecting mechanical unit for jogging

Jogging properties

If your system has more than one robot, that is additional robots or additional axes, then you need to select which mechanical unit to jog when using the joystick.

There are three ways to select mechanical unit:

• Using the Select mechanical unit button.

• Using the Jogging window on the ABB menu.

• Using the Quickset menu Mechanical unit , see

Program Editor on page 63 .

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.

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 77

In manual mode, the Quickset menu button displays which mechanical unit is selected.

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

Selecting mechanical unit using the hard button

Press the Select mechanical unit button to change unit. One press on the button changes to the next mechanical unit, as steps in a cycle.

xx0900000051

Selecting mechanical unit in the Jogging window

Use this procedure to select a mechanical unit to jog in the Jogging window.

Action

On the ABB menu, tap Jogging .

Continues on next page

132 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Action

Tap Mechanical Unit .

4 Jogging

4.6.1 Selecting mechanical unit for jogging

Continued en0400000653

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

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

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.

Related information

If the system uses Multitasking , and has more than one motion task, and uses more than one mechanical unit, then the selected mechanical unit can be switched automatically when switching between Program Editor windows. See section

Mechanical units can be activated or deactivated with the Activate function in the

Jogging window.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

133

4 Jogging

4.6.2 Selecting motion mode

4.6.2 Selecting motion mode

Motion mode

There are three ways to select motion mode:

1 Using the Toggle motion mode button.

2 Using the Jogging window on the ABB menu.

3 Using the Quickset menu Mechanical unit , see

Joystick directions on page 129 .

Selecting motion mode using the toggle button

Press the Toggle motion mode reorient/linear button to switch motion mode.

xx0900000052

Selecting motion mode in the Jogging window

Use this procedure to select motion mode in the Jogging window.

Information

Action

On the ABB menu, tap 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.

Related information

134 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

4 Jogging

4.6.3 Selecting tool, work object, and payload

4.6.3 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

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 .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

135

4 Jogging

4.6.4 Setting the tool orientation

4.6.4 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

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 135

Press and hold the three-position 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.

136 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

4 Jogging

4.6.5 Jog axis by axis

4.6.5 Jog axis by axis

Jogging axis by axis

There are three ways to select axis for jogging.

• Using the Toggle motion mode axis group button.

• Using the Jogging window on the ABB menu.

• Using the Quickset menu Mechanical unit , see

Illustration of axes and joystick directions on page 124

In manual mode, the Quickset menu button displays which axis group is selected.

How to use the joystick when jogging axis by axis is displayed in the Joystick directions area. See

Examples of use

Use axis by axis jogging when you need to:

• Move the mechanical unit out of a hazardous position.

• Move robot axes out of singularities.

• Position axes for fine calibration.

Selecting axis group using the toggle button

Press the Toggle motion mode axis group button to switch motion mode.

xx0900000053

Selecting axis group in the Jogging window

Use this procedure to select axis group in the Jogging window.

Action

On the ABB menu, tap Jogging .

Tap Motion Mode .

Tap on the axis group 1-3 or 4-6 and then tap OK .

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 136

when finished.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

137

4 Jogging

4.6.6 Selecting coordinate system

4.6.6 Selecting coordinate system

Coordinate systems for jogging

The coordinate system most suitable for your jogging depends on many things.

See section

Coordinate systems for jogging on page 123

, for more information.

There are two ways to select coordinate system:

• Using the Jogging window on the ABB menu.

• Using the Quickset menu Mechanical unit , see

Quickset menu, Increment on page 84

Prerequisites

Select motion mode suitable for the intended jogging.

Stationary tools in the tool coordinate system

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.

Selecting coordinate system

Use this procedure to select coordinate system in the Jogging window.

Action

On the ABB menu, tap Jogging .

Tap Coordinate System .

Tap to select a coordinate system.

Tap OK .

138 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

4 Jogging

4.6.7 Locking the joystick in specific directions

4.6.7 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

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.

Action

On the ABB menu, tap Jogging .

Tap Joystick lock .

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

139 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

4 Jogging

4.6.7 Locking the joystick in specific directions

Continued

Unlocking all axes

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

Action

On the ABB menu, tap Jogging .

Tap Joystick lock .

Tap None , then tap OK .

140 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

4 Jogging

4.6.8 Incremental movement for precise positioning

4.6.8 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.

There are three ways to select the increment size:

• Using the Toggle increments button.

• Using thee Jogging window on the ABB menu.

• Using the Quickset menu Increments , see

To use the toggle button you must first select an increment size in the Jogging window or Quickset menu.

Selecting increments using the toggle button

Press the Toggle increments button to switch increment size, you toggle between no increments and the increment size you previously selected in the Jogging window.

xx0900000054

Selecting increments in the Jogging window

Use this procedure to select the incremental movement size using the Jogging window.

Action

On the ABB menu, tap Jogging .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

141

4 Jogging

4.6.8 Incremental movement for precise positioning

Continued

Action

Tap Increment .

en0400000971

Tap the desired increment mode, see description in section

Incremental movement sizes on page 142

Tap OK .

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°

142 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

4 Jogging

4.6.9 Reading the exact position

4.6.9 Reading the exact position

About positions and revolution counters

The exact position of the robot is determined using the position of the resolvers and counters that count the number of resolver revolutions. These are called revolution counters.

If the robot is correctly calibrated then the current position is automatically calculated at start.

CAUTION

If the positions are displayed in red text then the values from the revolution counters are lost and instead the values stored on the SMB are displayed. Be careful when jogging the robot if the values are displayed in red text. Watch the robot closely and do not use the displayed values! If the mechanical unit is uncalibrated then the actual position can be very different from the position values stored by the SMB. You must update the revolution counters before a program can be started. See

Updating revolution counters on page 296

Note

If no positions are displayed then the mechanical unit is uncalibrated. Instead the text Selected mechanical unit is not calibrated is displayed.

Note

When updating the revolution counters, the ongoing RAPID instruction or function is interrupted, and the path is cleared.

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.

Reading the exact position

This procedure describes how to read the exact position.

Action

On the ABB menu tap .

Jogging .

Continues on next page

143 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

4 Jogging

4.6.9 Reading the exact position

Continued

Action

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

See illustration in

Jogging on page 58

Position format

The position can be displayed in different formats. Tap Position Format to change settings.

The Position can be displayed relative the following frames:

• World

• Base

• Work object

The Orientation format can be set to:

• Quaternion

• Euler angles

The Position angle format can be set to:

• Angles

The Presentation angle unit can be set to:

• Degrees

• Radians

144 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

4 Jogging

4.6.10 Aligning tools

4.6.10 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.

Action

On the ABB menu, tap Jogging .

Make sure that the right tool is active and then tap Align...

en0500001548

Select a coordinate system to align the selected tool to.

Press and hold the three-position enabling device and then tap and hold Start Align to start aligning the tool.

Tap Close when completed.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

145

This page is intentionally left blank

5 Programming and testing

5.1 Before you start programming

5 Programming and testing

5.1 Before you start programming

Programming tools

You can use both the FlexPendant and RobotStudio for programming. The

FlexPendant is best suited for modifying programs, such as positions and paths, while RobotStudio is preferred for more complex programming.

How to program using RobotStudio is described in Operating manual - RobotStudio .

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.

WARNING

It is important to always define the actual tool load and, when used, the payload of the robot (for example a gripped part). Incorrect definitions of load data can result in overloading of the robot mechanical structure.

When incorrect load data is specified, it can often lead to the following consequences:

• The robot will not be used to its maximum capacity

• Impaired path accuracy including a risk of overshooting

• Risk of overloading the mechanical structure

The controller continuously monitors the load and writes an event log if the load is higher than expected. This event log is saved and logged in the controller memory.

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 before you start programming. As you add more objects later you also need to define the corresponding coordinate systems.

Tip

For more details about the RAPID language and structure, see Technical reference manual - RAPID Overview and Technical reference manual - RAPID Instructions,

Functions and Data types .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

147

5 Programming and testing

5.2 Using RAPID programs

5.2 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.

Action

Start by creating a RAPID program.

Edit your program.

Information

How to create a RAPID program is detailed in section

Handling of instructions on page 162 .

Proceed as detailed in section

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

How to view, add, or delete a module is detailed in section

Handling of modules on page 153 .

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

How to add or delete a routine is detailed in section

Handling of routines on page 157 .

When programming you may want to work with:

• Tools

• Work objects

• Payloads

Also read the following sections:

•

Creating a tool on page 177

•

Creating a work object on page 192 .

•

Creating a payload on page 200

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 the RAPID manuals.

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

Proceed as detailed in section

page 206 .

Testing on

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 menu on page 54

How to modify positions in manual mode is described in section

Modifying positions in the Program Editor or Production Window on page 264 .

Programs that are no longer required may be removed.

Running the program

This procedure specifies how to use an existing RAPID program.

Action

Load an existing program.

Information

Described in section

Starting programs on page 241 .

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

Described in section

Quickset menu, Run

Mode on page 85

Continues on next page

148 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.2 Using RAPID programs

Continued

Action

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

Information

Described in section

Starting programs on page 241

and in

Using multitasking programs on page 245 .

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

Proceed as detailed in section

Stopping programs on page 244 .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

149

5 Programming and testing

5.3.1 Handling of programs

5.3 Programming concept

5.3.1 Handling of programs

Overview

This section details how to perform normal handling of robot programs. It describes 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. Note that the following procedures describe a single task system, i.e. only one task is available.

How to create a new program when no program is available is detailed in section

Creating a new program on page 150

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 unless otherwise stated. How to set another default path is detailed in section

Setting default paths on page 100

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.

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.

Continue by adding instructions, routines, or modules.

A new program is created.

Continues on next page

150 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.3.1 Handling of programs

Continued

Loading an existing program

This section describes how to load an existing program.

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 loaded program.

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.

Action

On the ABB menu, tap Program Editor .

Tap Tasks and Programs .

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 .

Continues on next page

151 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.3.1 Handling of programs

Continued

Renaming a loaded program

This section describes how to rename a loaded program.

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 .

Deleting a program

This section describes how to delete a program.

Action

On the ABB menu, tap Program Editor .

Tap Tasks and Programs .

Tap File and select Delete Program .

A confirmation dialog is displayed.

Tap OK to delete, or Cancel to keep the program intact.

152 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.3.2 Handling of modules

5.3.2 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.

Action

On the ABB menu, tap Program Editor .

Tap Modules .

Tap File , then tap New Module .

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 .

How to later switch between these types is detailed in section

Changing type of module on page 155 .

Continues on next page

153 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.3.2 Handling of modules

Continued

Loading an existing module

This section describes how to load an existing module.

Action

On the ABB menu, tap Program Editor .

Tap Modules .

Tap File , then Load Module .

4 en0400000689

Locate the module to be loaded. See section

FlexPendant Explorer on page 56

. A default path may be defined as detailed in section

Setting default paths on page 100 .

Tap OK to load the selected module.

The module is loaded.

Saving a module

This section describes how to save a module.

Action

On the ABB menu, tap Program Editor .

Tap Modules and tap to select the module you want to load.

Continues on next page

154 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Action

Tap File , then Save Module As...

5 Programming and testing

5.3.2 Handling of modules

Continued 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 56

. The default location is on the controller disk, but any other location may be set as default as detailed in section

Setting default paths on page 100 .

Then tap OK .

The module is saved.

Renaming a module

This section describes how to rename a module.

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 .

Changing type of module

This section describes how to change the type of module.

Action

On the ABB menu, tap Program Editor .

Tap Modules and select the module to be changed.

Tap File , then Change declaration...

Tap Type and select module type.

Continues on next page

155 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.3.2 Handling of modules

Continued

Action

Tap OK .

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.

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 154 .

156 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.3.3 Handling of routines

5.3.3 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.

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.

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 158

If NO; proceed to the next step.

Select module to add the routine to.

Continues on next page

157 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.3.3 Handling of routines

Continued

Action

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.

Action

In the routine declaration, tap ...

to define parameters.

A list of defined parameters is displayed.

en0400000693

Continues on next page

158 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.3.3 Handling of routines

Continued

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.

en0400000695

3 Use the soft keyboard to enter the name of the new parameter and then tap OK .

The new parameter is displayed in the list.

en0400000696

4 Tap to select a parameter. To edit values, tap the value.

Continues on next page

159 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.3.3 Handling of routines

Continued

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.

Action

On the ABB menu, tap Program Editor .

Tap Routines .

Highlight the routine by tapping it.

Tap File , then Copy Routine .

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 157 .

Changing the declaration of a routine

This section describes how to change the declaration of a routine.

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 157

Moving a routine

This section describes how to move a routine to another module.

Action

On the ABB menu, tap Program Editor .

Tap Routines .

Highlight the routine by tapping it.

Tap File , then Move Routine...

Select task and module. Then tap OK .

Deleting a routine

This section describes how to delete a routine from memory.

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.

Continues on next page

160 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.3.3 Handling of routines

Continued

Action

Tap:

• OK to delete the routine without saving any changes made to it.

• Cancel to revert without deleting the routine.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

161

5 Programming and testing

5.3.4 Handling of instructions

5.3.4 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 Technical reference manual - RAPID Instructions, Functions and Data types . 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.

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.

4 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 .

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.

Continues on next page

162 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.3.4 Handling of instructions

Continued

Action

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.

Action

Tap the instruction to edit.

en0400000699

2 Tap Edit .

en0400000701

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

163

5 Programming and testing

5.3.4 Handling of instructions

Continued

Action

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.

en0400000702

4 Tap the argument to be changed.

A number of options are displayed.

en0400000703

Tap an existing data instance to select and then tap OK to complete, or tap Expression

Continues on next page

164 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.3.4 Handling of instructions

Continued

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.

Action

Tap to select the argument or instruction you want to copy.

To select more than one row: select the first row, tap Select Range in the Edit menu and then tap the last row.

Tap Edit and then 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 .

Cutting an instruction

This section describes how to cut an instruction.

Action

Tap to select the instruction you want to cut.

To select more than one row: select the first row, tap Select Range in the Edit menu and then tap the last row.

Tap Edit and then tap Cut .

Changing motion mode for a move instruction

This section describes how to change the motion mode for a move instruction.

Action

Tap to select the move instruction you want to change and then tap Edit .

Tap Change to MoveJ or Change to MoveL .

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 .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

165

5 Programming and testing

5.3.5 Example: Add movement instructions

5.3.5 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.

C en0400000801

First point

Robot movement Speed data v50 = speed 50mm/s

Zone z50 = (50mm)

Add movement instructions

This section details how to add movement instructions.

Action

Jog the robot to the first point.

Information

Tip: Use only left-right/up-down joystick movements to jog in a square.

In the program editor, tap Add Instruction .

Tap MoveL to insert a MoveL instruction.

Repeat for the next four positions of the square.

For the first and last instruction. Tap z50 in the instruction, tap Edit and then Change selected to Fine . Tap OK

Result

Your program code should look like this:

Proc main()

MoveL *, v50, fine, tool0;

MoveL *, v50, z50, tool0;

MoveL *, v50, fine, tool0;

End Proc;

166 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.3.6 About the Program and Motion Pointers

5.3.6 About the Program and Motion Pointers

The Program Pointer

The Program Pointer (PP) indicates the instruction with which the program will start when you press any of the Start , Forward , or Backward buttons on the

FlexPendant.

Program execution continues from the instruction where the Program Pointer is.

However, if the cursor is moved to another instruction when the program is stopped, the Program Pointer can be moved to the position of the cursor (or the cursor can be moved to the Program Pointer), and execution can be restarted from there.

The Program Pointer is shown as a yellow arrow to the left of the program code in the Program Editor and Production Window .

The Motion Pointer

The Motion Pointer (MP) indicates the instruction that the robot is currently executing. This is normally one or more instructions after the Program Pointer, as the system executes and calculates the robot path faster than the robot moves.

The Motion Pointer is shown as a small robot to the left of the program code in the

Program Editor and in the Production Window .

The cursor

The cursor can indicate a complete instruction or any of the arguments.

The cursor is shown as blue highlighting of the program code in the Program

Editor .

Program Editor

If you toggle between the Program Editor and another view and back again, the

Program Editor will show the same part of the code as long as the program pointer has not been moved. If the program pointer is moved, the Program Editor shows the code at the position of the program pointer.

The same behavior applies to the Production Window .

Related information

Production Window on page 60 .

Program Editor on page 63 .

Stepping instruction by instruction on page 214 .

Starting programs on page 241 .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

167

5 Programming and testing

5.4.1 Viewing data in specific tasks, modules, or routines

5.4 Data types

5.4.1 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.

Action

On the ABB menu, tap Program Data .

Tap Change Scope .

The following screen is displayed:

168 en0400000661

Select the required scope by selecting:

• Built-In Data Only : Shows all data types used by the specific system

• Current execution : Shows all data types used in the current execution

• 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.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.4.2 Creating new data instance

5.4.2 Creating new data instance

Creating new data instance

This section details how to create new data instances of data types.

Action

On 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 .

en0400000663

Tap ...

the right of Name to define the data instance’s name.

Name

Tap the Scope menu to set accessibility for the data instance. Select:

• Global - reachable by all tasks

• Local - reachable within the module

• Task - reachable within the 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.

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.

Continues on next page

169 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.4.2 Creating new data instance

Continued

Action

Tap OK .

170 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.4.3 Editing data instances

5.4.3 Editing data instances

Overview

This section describes how to view data instances in the Program Data window.

It also details how to edit, delete, change declaration of, copy, and define a data instance.

For the data types tooldata , wobjdata and loaddata also see sections

Tools on page 175 ,

Work objects on page 191

Payloads on page 200

Viewing data instances

This section details how to view the available instances of a data type.

Action

On the ABB menu, tap Program Data .

Tap the data type you want view and then tap Show Data .

Tap the data instance you want to edit, and then tap Edit .

en0400000671

4 Depending on what you want to do, tap one of the following menu items:

• Tap Delete to remove the data instance.

• Tap Change Declaration to change the declaration of the data instance.

• Tap Change Value to edit the value of the data instance.

• Tap Copy to copy the data instance.

• Tap Define to define the instance (only available for tooldata , wobjdata and loaddata ).

• Tap Modify Position to modify a position (only available for robtarget and jointtarget ).

Proceed as described in the respective section following below.

Continues on next page

171 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.4.3 Editing data instances

Continued

Editing the value of a data instance

This section describes how to edit a data instance value.

Action

Tap Change Value to open the instance.

Information

Tap the value to open a keyboard or list of choices.

The way to edit a value depends on the data type and possible values, for instance text, numbers, predefined values etc.

Select or enter a new value.

Tap OK .

Note

If the value of a persistent variable is changed at any point in a running program, the Program Editor will still show the old value until the program stops. The

Program Data view, however, always shows the current value of persistent variables. See Persistent declaration in the Technical reference manual - RAPID

Overview for further information.

Deleting a data instance

This section details how to delete a data instance.

Note

A data instance can be of type tool , work object , payload or others.

Action

Tap Delete in the menu for the data instance to be deleted, as detailed in section

Viewing data instances on page 171 .

A dialog box is displayed.

Tap Yes if you are sure the data instance is to be deleted.

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.

Continues on next page

172 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.4.3 Editing data instances

Continued

Changing the declaration of a data instance

This section details how to change the declaration of a data instance.

Action

Tap Change Declaration in the menu for the data instance to be deleted, as detailed in section

Viewing data instances on page 171

en0400000672

2 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 a data instance

This section details how to copy a data instance.

Action

Tap Copy in the menu for the data instance to be copied, as detailed in section

Viewing data instances on page 171 .

A copy of the data instance is created.

The copy has the same values as the original, but the name is unique.

Defining a data instance

How to define the tool frame or work object frame is described in the sections

Defining the tool frame on page 180

and

Defining the work object coordinate system on page 193 .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

173

5 Programming and testing

5.4.3 Editing data instances

Continued

Modifying position of a data instance

Only instances of data types robtarget and jointtarget can use the function

Modify Position . The currently active work object and tool will be used in the operation.

More information about modifying positions is detailed in

Modifying and tuning positions on page 263 .

Note

Make sure that the correct work object and tool are selected when modifying positions in the Program Data window. This is not verified automatically by the system.

174 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.5.1 What is a tool?

5.5 Tools

5.5.1 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 can be used by the robot must be measured and its data stored in order to achieve accurate positioning of the tool center point.

WARNING

When incorrect load data is specified, it can often lead to the following consequences:

• The robot will not be used to its maximum capacity

• Impaired path accuracy including a risk of overshooting

• Risk of overloading the mechanical structure

The controller continuously monitors the load and writes an event log if the load is higher than expected. This event log is saved and logged in the controller memory.

Illustration en0400000803

Tool side

Robot side

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

175

5 Programming and testing

5.5.2 What is the tool center point?

5.5.2 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.

xx0300000604

Description

Moving TCP

Stationary TCP

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 can 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 can be defined in relation to, for example 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, for example when a stationary spot welding gun is used. In such cases the TCP can be defined in relation to the stationary equipment instead of the moving manipulator.

176 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.5.3 Creating a tool

5.5.3 Creating a tool

What happens when you create a tool?

When you create a new tool a variable of the data type tooldata is created. The variable name will be the name of the tool. For more information on data types, see Technical reference manual - RAPID Instructions, Functions and Data types .

The new tool has initial default values for mass, frame, orientation etc., which must be defined before the tool can be used.

How to create a tool

The tool center point of the default tool (tool0) is in the center of the robot's mounting flange and shares the orientation of the robot base.

By creating a new tool you define another tool center point. For more information about tools and the tool center points see

What is a tool? on page 175

and

What is the tool center point? on page 176 .

en0400000779

A Tool center point, TCP, for tool0

Action

On the ABB menu, tap Jogging .

Tap Tool to display the list of available tools.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

177

5 Programming and testing

5.5.3 Creating a tool

Continued

Action

Tap New to create a new tool.

4 en0300000544

Enter values for each field, see table below.

Tap OK .

Tool declaration settings

If you want to change...

the name of the tool the scope the storage type the module

then...

tap ...

button next to Name

Recommendation

Tools are automatically named tool followed by a running number, for example tool10 or tool21 .

You are recommended to change this to something more descriptive such as gun, gripper or welder.

select the preferred scope from the menu

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.

Tools should always be global, as to be available to all modules in the program.

Tool variables must always be persistent.

select the module in which this tool should be declared from the menu

Continues on next page

178 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.5.3 Creating a tool

Continued

If you want to change...

the size of the data array's axes then...

tap ...

button next to Dimension

Recommendation

Note

The created tool is not useful until you have defined the tool data (TCP coordinates, orientation, weight etc.). See

Editing the tool data on page 184

and

LoadIdentify, load identification service routine on page 224

to learn more about how to do it.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

179

5 Programming and testing

5.5.4 Defining the tool frame

5.5.4 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.

You also need to decide which method to use for the tool frame definition.

Available methods

There are three different methods which can be used when defining the tool frame.

All three require that you define the cartesian coordinates of the tool center point.

What differs is how the orientation is defined.

If you want to...

set the orientation in X and Z axes

...then select set the orientation the same as the orientation of the robot’s mounting plate

TCP (default orient.) set the orientation in Z axis TCP&Z

TCP&Z,X

How to select a method

This procedure describes how to select the method to be used when defining the tool frame.

Action

On the ABB menu, tap Jogging .

Tap Tool to display a list of available tools.

Select the tool you want to define.

In the Edit menu, tap Define

Continues on next page

180 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.5.4 Defining the tool frame

Continued

Action

In the dialog box which appears, select the method to use.

en0600003147

Select the number of approach points to use. Usually 4 points is enough. If you choose more points to get a more accurate result, you should be equally careful when defining all of them.

See

How to proceed with tool frame definition on page 182

for information on how to gather positions and perform the tool frame definition.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

181

5 Programming and testing

5.5.4 Defining the tool frame

Continued

How to proceed with tool frame definition

This procedure describes how to define the tool center point in Cartesian coordinates.

en0400000906

Action

Jog the robot to an appropriate position,

A, for the first approach point.

Information

Use small increments to accurately position the tool tip as close to the reference point as possible.

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 the best result. Just changing the tool orientation will not give as good a result.

If the method you are using is TCP&Z or

TCP&Z,X orientation must be defined as well.

If, for some reason, you want to redo the calibration procedure described in step 1-

4, tap Positions and then Reset All .

Follow the instructions in

How to define elongator points on page 183 .

Continues on next page

182 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.5.4 Defining the tool frame

Continued

Action Information

When all points are defined you can save them to file, which enables you to reuse them later. On the Positions menu, tap

Save .

Tap OK . The Calculation Result dialog box will now be displayed, asking you to cancel or to confirm the result before it is written to the controller.

For further information see

Is the calculated result good enough? on page 183

How to define elongator points

This procedure describes how to define the orientation of the tool frame by specifying the direction of the z and/or x axis. You need to do this only if you the tool orientation should differ from that of the robot base. The tool coordinate system by default resembles the coordinate system of tool0, as illustrated in

Measuring the tool center point on page 185

Action

Without changing the orientation of the tool, jog the robot so that the reference 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 should be defined.

Is the calculated result good enough?

The Calculation Result dialog box displays the calculated result of the tool frame definition. You have to confirm that you accept the result before it can take effect in the controller. The alternative is to redo the frame definition in order to achieve a better result. The result Mean Error is the average distance of the approach points from the calculated TCP (tool center point).

Max Error is the maximum error among all approach points.

It is hard to tell exactly what result is acceptable. It depends on the tool, robot type etc. you are using. Usually a mean error of a few tenths of a millimeter is a good result. If the positioning has been undertaken with reasonable accuracy the result will be okay.

As the robot is used as a measuring machine, the result is also dependent on where in the robot’s working area the positioning has been done. Variation of the actual TCP up to a couple of millimeters (for large robots) can be found between definitions in different parts of the working area.The repeatability of any following

TCP calibrations will thus increase if these are done close to the preceding ones.

Note that the result is the optimal TCP for the robot in that working area, taking into account any discrepancies of the robot in the configuration at hand.

Tip

A common way to check that the tool frame has been correctly defined is to perform a reorientation test when the definition is ready. Select the reorient motion mode and the tool coordinate system and jog the robot. Verify that the tool tip stays very close to the selected reference point as the robot moves.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

183

5 Programming and testing

5.5.5 Editing the tool data

5.5.5 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

LoadIdentify, load identification service routine on page 224

, or

Displaying the tool data

This section details how to display the tool data.

Action

On the ABB menu, tap Jogging .

Tap Tool to display the list of available tools.

Tap the tool you want to edit, then tap 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.

Continues on next page

184 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.5.5 Editing the tool data

Continued

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 180

. If you use this method, you do not have to write any values for the frame 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.

en0400000881

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

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

Action

Enter the cartesian coordinates of the tool center point's position.

Instance tframe.trans.x

tframe.trans.y

tframe.trans.z

Unit

[mm]

Continues on next page

185 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.5.5 Editing the tool data

Continued

Action Instance

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

None

[kg]

[mm]

None

[kgm

]

186 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.5.6 Editing the tool declaration

5.5.6 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

Action

On the ABB menu, tap Jogging .

Tap Tool to see the list of available tools.

Tap the tool you want to edit, then tap 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 177 .

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.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

187

5 Programming and testing

5.5.7 Deleting a tool

5.5.7 Deleting a tool

Deleting a tool

For more information about deleting a tool , see

Deleting a data instance on page 172 .

188 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.5.8 Setup for stationary tools

5.5.8 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.

Action

On the ABB menu, tap Jogging .

Tap Tool to display the list of available tools.

Tap the tool you want to edit, then tap 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.

Action

In the Jogging window, tap Work object to display the list of available work objects.

Tap the work object you want to edit, then tap 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.

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...

...but now references the...

user coordinate system user coordinate system (no change) world coordinate system robot’s mounting plate robot’s mounting plate world coordinate system

Continues on next page

189 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.5.8 Setup for stationary tools

Continued

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.

en0400000990

190 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.6.1 What is a work object?

5.6 Work objects

5.6.1 What is a work object?

Illustration

Description en0400000819

A work object is a coordinate system with specific properties attached to it. It is mainly used to simplify programming 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.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

191

5 Programming and testing

5.6.2 Creating a work object

5.6.2 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 Technical reference manual - RAPID Instructions, Functions and Data types .

This is detailed in section

What is a work object? on page 191 .

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 declaration on page 198 .

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...

the work object’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 work object should be declared 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.

192 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.6.3 Defining the work object coordinate system

5.6.3 Defining the work object coordinate system

Overview

Defining a work object means that the robot is used to point out the location of it.

This is done by defining three positions, two on the x-axis and one on the y-axis.

When defining a work object you can use either the user frame or the object frame or both. The user select frame and the object frame usually coincides. If not, the object frame is displaced from the user frame.

How to select method

This procedure describes how to select method for defining either user frame or object frame or both. Note that this only works for a user created work object, not the default work object, wobj0. Defining work object can also be done from the

Program Data window.

Action

On the ABB menu, tap Jogging

Tap Work object to display the list of available work objects.

Tap the work object you want to define, then tap Edit .

In the menu, tap Define....

Select method from the User method and/or the Object method menu. See

How to define the user frame on page 194

and

How to define the object frame on page 195

en0400000893

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

193

5 Programming and testing

5.6.3 Defining the work object coordinate system

Continued

How to define the user frame

This section details how to define the user frame.

en0400000887

The x axis will go through points X1-X2, and the y axis through Y1.

Action

In the User method pop up menu, tap 3 points .

Information

Press the three-position enabling device and jog the robot to the first (X1, X2 or Y1) point that you want to define.

Large 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.

Continues on next page

194 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.6.3 Defining the work object coordinate system

Continued

How to define the object frame

This section describes how to define the object frame if you want to displace it from the user frame.

en0400000899

The x axis will go through points X1-X2, and the y axis through Y1.

Action

In the Object method pop up menu, tap 3 points .

See steps 2 to 4 in the description of

How to define the user frame on page 194

How to save the defined positions

Normally the defined positions are only used as temporary positions by the controller to calculate the position of the work object and are then discarded.

However, the positions can also be saved to a program module for later use or analysis.

When saving the positions a new program module is created where the positions are stored with predefined names given by the controller. The names of the positions can be changed afterwards, but when loading the positions it is recommended to use the predefined names.

Note

Only the positions (robtargets) are saved. Make sure to note which tool was used when modifying the defined positions.

Action

When the work object frame definition is completed and all positions have been modified, tap OK .

In the Save Modified Points dialog, tap Yes .

Tap ABC to change the name of the program module, tap OK to accept the name.

Continues on next page

195 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.6.3 Defining the work object coordinate system

Continued

Action

The names of the positions and the module is displayed in the Save dialog, tap OK .

How to load defined positions

In some cases it is not practical or possible to use the robot to define the positions.

Then the positions can be defined or calculated elsewhere and loaded to the Work

Object Frame Definition dialog.

Positions from any program module can be can be loaded, but is recommended to use the module from the Save Modified Points dialog with predefined position names given by the controller.

CAUTION

Make sure that the correct tool and work object is activated in the Work Object

Frame Definition dialog before loading any positions.

Action

In the Work Object Frame Definition dialog, tap Positions and Load .

Tap the module that holds the calibration points, tap OK .

If the controller finds all or any predefined positions in the module, the positions are automatically loaded to the correct user or object point.

In the Load dialog, tap OK .

If some positions are missing or do not have the correct names, the controller cannot load the positions automatically so the user is asked to match the positions manually.

Tap each point in the list to assign the positions manually from the drop down list. Tap

OK .

If necessary, use Modify Position to define any remaining points that could not be loaded.

196 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.6.4 Editing the work object data

5.6.4 Editing the work object data

Overview

Use the work object data definition to set the position and rotation of the user and object frames.

How to display the work object data

Action

On the ABB menu, tap Jogging .

Tap Work object to display the list of available work objects.

Tap the work object you want to edit, then tap Edit .

Tap Change Value.

The data that defines the work object appears.

How to set user and object frame values manually

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 193 .

You can however edit the values manually using the guide below.

Unit mm

Values

The cartesian coordinates of the position of the object frame

Instance oframe.trans.x

oframe.trans.y

oframe.trans.z

The object frame orientation oframe.rot.q1

oframe.rot.q2

oframe.rot.q3

oframe.rot.q4

The cartesian coordinates of the position of the user frame uframe.trans.x

uframe.trans.y

uframe.trans.z

The user frame orientation uframe.rot.q1

uframe.rot.q2

uframe.rot.q3

uframe.rot.q4

Note

Editing work object data can also be done from the Program Data window.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

197

5 Programming and testing

5.6.5 Editing the work object declaration

5.6.5 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

Action

On the ABB menu, tap Jogging .

Tap Work object to see the list of available work objects.

Tap the work object you want to edit, then tap Edit .

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 192

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.

198 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.6.6 Deleting a work object

5.6.6 Deleting a work object

Deleting a work object

For more information about deleting a work object , see

Deleting a data instance on page 172 .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

199

5 Programming and testing

5.7.1 Creating a payload

5.7 Payloads

5.7.1 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 Technical reference manual - RAPID Instructions, 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.

Action

On the ABB menu tap Jogging .

Tap Payload or Total Load to display the list of available payloads.

Note

Total Load is displayed only when the value of ModalPayLoadMode is set to 0 and the mechanical units are TCP robots. See

Setting the value for ModalPayLoadMode on page 201 .

Tap New to create a new payload and enter the data. See

Payload declaration settings on page 201 .

Tap OK .

WARNING

When incorrect load data is specified, it can often lead to the following consequences:

• The robot will not be used to its maximum capacity

• Impaired path accuracy including a risk of overshooting

• Risk of overloading the mechanical structure

The controller continuously monitors the load and writes an event log if the load is higher than expected. This event log is saved and logged in the controller memory.

Continues on next page

200 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.7.1 Creating a payload

Continued

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.

Setting the value for ModalPayLoadMode

This procedure describes how to modify the value of ModalPayLoadMode :

1 On the ABB menu, tap Control Panel and then Configuration .

2 Select Controller .

3 Select the type System Misc and tap.

4 Select ModalPayLoadMode and then tap Edit .

5 Tap the parameter Value twice and set to 0 .

6 Click OK .

7 Tap Yes to the question The changes will not take effect until the controller is warm started. Do you want to restart now?

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

201

5 Programming and testing

5.7.2 Editing the payload data

5.7.2 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

LoadIdentify, load identification service routine on page 224

, or

Displaying the payload definition

Action

On the ABB menu, tap Jogging .

Tap Payload to display the list of available payloads.

Tap the payload you want to edit, then tap Edit .

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 LoadIdentify. How to run a service routine is described in section

Creating a payload on page 200 .

Action

Enter the weight of the payload.

Enter the payload’s center of gravity.

Instance load.mass

load.cog.x

load.cog.y

load.cog.z

Enter the orientation of the axis of moment.

Enter the payload’s moment of inertia.

Tap OK to use the new values, Cancel to leave the data unchanged.

ix iy iz load.aom.q1

load.aom.q2

load.aom.q3

Unit

[kg]

[mm]

[kgm

]

Using the PayLoadsInWristCoords parameter

By using the PayLoadsInWristCoords parameter, the loaddata for payloads can be specified relative to the wrist instead of the active TCP or work object. This can be useful if several tool or TCP or work objects (when tool is stationary) are used for one payload. In this case only one load identification is needed instead of one for each tool or TCP or work object. Thus it is possible to use the same payload loaddata for any robhold or stationary tool being active. This saves the time (for example, during commissioning).

Continues on next page

202 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.7.2 Editing the payload data

Continued

For more information about

PayLoadsInWristCoords

, see Technical reference manual - System parameters and Technical reference manual - RAPID Instructions,

Functions and Data types .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

203

5 Programming and testing

5.7.3 Editing the payload declaration

5.7.3 Editing the payload declaration

Overview

Use the declaration to change how the payload variable can be used in the program’s modules.

Displaying the payload declaration

Action

On the ABB menu, tap Jogging .

Tap Payload to see the list of available payloads.

Tap the payload you want to edit, then tap Edit .

In the menu, tap Change declaration .

The payload’s declaration appears. See

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.

204 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.7.4 Deleting a payload

5.7.4 Deleting a payload

Deleting a payload

For more information about deleting a payload , see

Deleting a data instance on page 172

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

205

5 Programming and testing

5.8.1 About the automatic mode

5.8 Testing

5.8.1 About the automatic mode

What is the automatic mode?

In automatic mode the safety function of the three-position enabling device is bypassed so that the manipulator is allowed to move without human intervention.

WARNING

Prior to selecting automatic mode, any suspended safeguards shall be returned to their full functionality.

Tasks normally performed in the automatic mode

The following tasks are normally performed in automatic mode.

• Starting and stopping processes.

• Loading, starting, and stopping RAPID programs.

• Returning the manipulator to its path when returning to operation after an emergency stop.

• Backing up the system.

• Restoring backups.

• Cleaning tools.

• Preparing or replacing work objects.

• Performing other process oriented tasks.

Limitations in automatic mode

Jogging is not possible in automatic mode. There may be other specific tasks that should not be performed in automatic mode.

Consult your plant or system documentation to find out which specific tasks should not be performed in automatic mode.

Active safeguard mechanisms

For IRC5, both the general mode stop (GS) mechanisms, the automatic mode stop

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

Coping with process disturbances

Process disturbances may not only affect a specific manipulator 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 manipulator cell.

All remedial actions must be performed by personnel with good knowledge of the entire production line, not only the malfunctioning manipulator.

Continues on next page

206 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.8.1 About the automatic mode

Continued

Process disturbance examples

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

207

5 Programming and testing

5.8.2 About the manual mode

5.8.2 About the manual mode

What is the manual mode?

In manual mode the manipulator movement is under manual control. The three-position enabling device must be pressed to activate the motors of the manipulator, that is, enabling movement.

The manual mode is used when programming and for program verification.

There are two manual modes:

• Manual reduced speed mode, usually called manual mode.

• Manual full speed mode (not available in USA or Canada).

What is the manual reduced speed mode?

The three-position enabling device must be pressed to activate the motors of the manipulator.

WARNING

Wherever possible, the manual mode of operation shall be performed with all persons outside the safeguarded space.

What is the manual full speed mode?

In manual full speed mode, the manipulator can move in programmed speed but only under manual control.

The manual full speed mode is used for program verification only.

In manual full speed mode the initial speed limit is up to, but not exceeding, 250 mm/s. This is achieved by limiting the speed to 3% of the programmed speed.

Through manual control the speed can be increased up to 100%.

The three-position enabling device must be pressed to activate the motors of the manipulator, and the hold-to-run button must be pressed to start program execution.

WARNING

Wherever possible, the manual mode of operation shall be performed with all persons outside the safeguarded space.

Continues on next page

208 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.8.2 About the manual mode

Continued

Note that the manual full speed mode is optional and therefore not available in all robots.

Note

As per the updated standard, ISO 10218-1:2011 Robots and robotic devices –

Safety requirements for industrial robots – Part 1 Robots , the following adaptations are made to the manual full speed mode.

• Editing RAPID programs and jogging the manipulator are disabled.

Bypassed safeguard mechanisms

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

The three-position enabling device

In manual mode the motors of the manipulator are activated by the three-position enabling device on the FlexPendant. This way the manipulator can only move as long as the device is pressed.

The hold-to-run function

Tasks normally performed in manual reduced speed mode

The following tasks are normally performed in manual reduced speed mode.

• Jogging the manipulator back on its path when returning to operation after an emergency stop

• Correcting the value of I/O signals after error conditions

• Creating and editing RAPID programs

• Starting, stepping, and stopping program execution, for example while testing a program

• Tuning programmed positions

Continues on next page

209 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.8.2 About the manual mode

Continued

Tasks normally performed in manual full speed mode

As per the standard, ISO 10218-1:2011, the following tasks can be performed in the manual full speed mode.

• Starting and stopping program execution for final program verification

• Stepping program execution

• Setting speed (0–100%)

• Setting program pointer (to Main, to routine, to cursor, to service routine, etc.)

The following tasks cannot be performed in the manual full speed mode:

• Changing system parameter values

• Editing system data

210 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.8.3 Using the hold-to-run function

5.8.3 Using 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 three-position enabling device.

In order to run a program in manual full speed mode it is necessary, for safety reasons, to keep pressing both the three-position enabling device and the Start button. This hold-to-run function also applies when stepping through a program in manual full speed mode. When Start , Forward , and Backward buttons are used like this (press and hold) they are referred to as hold-to-run buttons. Some versions of the FlexPendant also have separate hold-to-run buttons.

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

Automatic mode

Pressing hold-to-run AND pressing the three-position 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.

Hold-to-run is not used in automatic mode.

Using the hold-to-run function

This instruction details how use the hold-to-run function in manual full speed mode.

Action

Press the three-position enabling device on the FlexPendant.

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 Start button is pressed.

If Forward or Backward was pressed, the program is executed step-by-step by alternately releasing and pressing the Forward/Backward button.

Note that the button must be pressed and held until the instruction is executed. If the button is released, program execution will stop immediately!

If the three-position enabling device is released, intentionally or by accident, the complete procedure must be repeated to enable running.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

211

5 Programming and testing

5.8.4 Running the program from a specific instruction

5.8.4 Running the program from a specific instruction

Overview

When starting a program the execution starts from the program pointer. To start from another instruction, move the program pointer to the cursor.

WARNING

When execution is started the robot will move to the first programmed position in the program. Make sure that the robot with TCP does not risk running into any obstacles!

Running the program from a specific instruction

Action

On the ABB menu, tap Program Editor.

Tap on the program step where you want to start, then tap Debug and then PP to

Cursor .

DANGER

Make sure that no personnel are in the robot working area.

Before running the robot, observe the safety information in section

Moving robots are potentially lethal on page 21 .

4 Press the Start button on the FlexPendant (see E in illustration below).

en0300000587

212 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.8.5 Running a specific routine

5.8.5 Running a specific routine

Overview

When starting a program the execution starts from the program pointer. To start from another routine, move the program pointer to the routine.

Prerequisites

In order to run a specific routine the module with the routine must be loaded and the controller must be in manual stopped mode.

Running a specific routine

This procedure describes how to run a specific routine by moving the program pointer.

Action

On the ABB menu, tap Program Editor .

Tap Debug and then PP to Routine to place the program pointer at the start of the routine.

Press the Start button on the FlexPendant.

Related information

How to run a service routine is described in

The same method can be used to run a specific routine in the task scope. See

Quickset menu, Step Mode on page 86 .

for detailed information.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

213

5 Programming and testing

5.8.6 Stepping instruction by instruction

5.8.6 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 Technical reference manual - 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.

Action Information

Select step mode using the Quickset menu.

Described in

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.

Continues on next page

214 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.8.6 Stepping instruction by instruction

Continued

Example of backward execution

The following 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 Technical reference manual - RAPID Instructions, Functions and Data types .

en0400001204

Program pointer

Motion pointer

Highlighting of the robtarget that the robot is moving towards, or already has reached.

When...

pressing the Backward button once pressing the ward

Backbutton again then...

stepping forward until the robot is in p50 the motion pointer will indicate p50 and the program pointer will indicate the next move instruction ( MoveL p60 ).

the robot will not move but the program pointer will move to the previous instruction ( MoveC p30, p40 ). This indicates that this is the instruction that will be executed the next time Backward is pressed.

the robot will move to p40 linearly with the speed v300.

The target for this movement (p40) is taken from the MoveC instruction. The type of movement (linear) and the speed are taken from the instruction below ( MoveL p50 ).

The motion pointer will indicate p40 and the program pointer will move up to MoveL p20 .

Continues on next page

215 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.8.6 Stepping instruction by instruction

Continued

When...

pressing the Backward button again then...

the robot will move circularly, via p30, to p20 with the speed v1000.

The target p20 is taken from the instruction MoveL p20 . The type of movement (circular), the circular point (p30) and the speed are taken from the MoveC instruction.

The motion pointer will indicate p40 and the program pointer will move up to

MoveL p10

pressing the ward

Backbutton again the robot will move linearly to p10 with the speed v1000.

The motion pointer will indicate p10 and the program pointer will move up to MoveJ p10 .

pressing the Forward button once the robot will not move but the program pointer will move to the next instruction ( MoveL p20 ).

pressing the Forward button again the robot will move to p20 with the speed v1000.

216 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.1 Running a service routine

5.9 Service routines

5.9.1 Running a service routine

Service routines

Service routines perform a number of common services. Which service routines are available depends on your system setup and available options. Please refer to your plant or cell documentation for more information.

Prerequisites

Service routines can only be started in manual reduced speed mode or in manual full speed mode.

The program must be stopped and there has to be a program pointer.

It is not possible to call a routine when in synchronized mode.

If the service routine contains parts that must be carried out in automatic mode, then the program pointer must not be moved manually before starting the service routine. The program pointer should be where the program flow was stopped.

WARNING

If a service routine is started in the middle of a stopped movement instruction

(that is, before the end position is reached), then the movement will be resumed when the execution of the service routine starts.

CAUTION

Note that once a service routine has started, aborting it might not resume the system to its previous state, as the routine may have moved the robot arm.

Running a service routine

This section describes how to execute a service routine or another routine in the task scope using Call Routine .

Action

On the ABB menu tap Program Editor .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

217

5 Programming and testing

5.9.1 Running a service routine

Continued

Action

On the Debug menu tap Call Routine .

en0400000884

3 The Call Service Routine dialog lists all predefined service routines.

The same dialog can however be used to run any routine in the task scope. Select All

Routines on the View menu to see all available routines.

en0400000885

4 Tap a service routine and then tap Go to .

The Program Editor will be displayed with the program pointer moved to the beginning of the selected routine.

Continues on next page

218 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.1 Running a service routine

Continued

Action

Press the Start button on the FlexPendant and follow the instructions displayed on the FlexPendant.

After execution of the routine the task is stopped and the program pointer is returned to where it was before the service routine started.

CAUTION

Press Cancel Call Rout if you need to interrupt the routine before it has finished executing. Before resuming normal program flow, however, you must see to it that the robot is correctly positioned. If the interrupted routine has moved it, you will need to take actions to return the robot to its position. See

Returning the robot to the path on page 254

for further information.

WARNING

Do not execute a service routine in the middle of a move or a weld.

If you execute a service routine in the middle of a movement, the unfinished movements will be completed before the called routine is executed. This can result in an unwanted movement.

If possible, step and complete the interrupted movement before the service routine is called. Otherwise save the current movement by adding StorePath and RestoPath in the service routine. The movement will then be completed after the service routine has ended and the program starts again.

However, it is not possible to save more than one interrupted movement each time as wanted, if the service routine would be called from an error handler with

StorePath and RestoPath .

Limitations

Besides service routines, Call Routine applies to all routines with the following criteria:

• Must be a procedure with empty parameter list. This means not a function and not a trap routine.

• Must be in the task scope, not local. If the procedure is local in a module the scope is restricted to that module, and the procedure is not visible from the task level.

• Must be in a loaded module, not installed. (Check the system parameter

Installed in the type Automatic Loading of Modules in the Controller topic.)

Related information

Battery shutdown service routine on page 221 .

LoadIdentify, load identification service routine on page 224

Service Information System, ServiceInfo service routine on page 223 .

Calibration Pendulum, CalPendulum service routine on page 222

Continues on next page

219 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.1 Running a service routine

Continued

For more information about

StorePath and

RestoPath

, see Technical reference manual - RAPID Instructions, Functions, and Data types .

220 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.2 Battery shutdown service routine

5.9.2 Battery shutdown service routine

When to use this service routine

For SMB units with 2-pole battery contact, it is possible to shut down the battery backup of the serial measurement board to save battery power during transportation or storage. This is the Bat_shutdown service routine.

For SMB units with 3-pole contact, this function shall not be used since the power consumption is so low that it is not needed.

Bat_shutdown

When the system is powered on again, the function is reset. The revolution counters will be lost and need an update but the calibration values will remain.

The consumption in ordinary shutdowns is then approximately 1 mA. When using sleep mode the consumption is reduced to 0.3 mA. When the battery is nearly discharged, with less then 3 Ah left, an alert is given on the FlexPendant and the battery should be replaced.

Tip

Before starting the service routine Bat_shutdown, run the robot to its calibration position. This will make it easier to recover after the sleep mode.

Related information

How to start a service routine is described in

Updating revolution counters on page 296 .

How to update the revolution counters is described in

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

221

5 Programming and testing

5.9.3 Calibration Pendulum, CalPendulum service routine

5.9.3 Calibration Pendulum, CalPendulum service routine

When to use this service routine

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.

CalPendulum

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the manual Operating manual - Calibration Pendulum .

Related information

Calibration Pendulum is described in full in the manual Operating manual - Calibration Pendulum . Specific information for each robot is described in the robot’s product manual.

222 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.4 Service Information System, ServiceInfo service routine

5.9.4 Service Information System, ServiceInfo service routine

When to use this service routine

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.

ServiceInfo

Maintenance is scheduled by setting the system parameters of the type SIS

Parameters . All system parameters are described in Technical reference manual - System parameters . More details about SIS is described in Operating manual - Service Information System .

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

Operating manual - Service Information System .

The system parameters for SIS are described in Technical reference manual - System parameters , chapter Motion .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

223

5 Programming and testing

5.9.5 LoadIdentify, load identification service routine

5.9.5 LoadIdentify, load identification service routine

When to use this service routine

The service routine LoadIdentify is used to automatically identify the data of loads mounted on the robot. The data can also be entered manually, but this requires information that may be difficult to calculate.

To run LoadIdentify, there are a number of things to consider. These are described on the following pages. There is also information on error handling and limitations described in this chapter.

WARNING

When incorrect load data is specified, it can often lead to the following consequences:

• The robot will not be used to its maximum capacity

• Impaired path accuracy including a risk of overshooting

• Risk of overloading the mechanical structure

The controller continuously monitors the load and writes an event log if the load is higher than expected. This event log is saved and logged in the controller memory.

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.

en0500001535

Upper arm load

Tool load

Payload

Before running the load identification for the payload, make sure that the tool load data is correctly defined first, for example by running LoadIdentify for the tool.

Continues on next page

224 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.5 LoadIdentify, load identification service routine

Continued

To identify the mass of B and C, axis 3 has to perform some movement. This means that to identify the mass, the upper arm load A must be known and correctly defined first.

To improve accuracy if the upper arm load A is mounted, input the known mass of B and C and choose the known mass method when identifying.

Configuration 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 and for axis 5 it is approximately

±30 degrees. For axis 6 the motion is performed around two configuration points.

The optimum value for the configuration angle is either +90 degrees or -90 degrees.

30°

30° 30° B

A en0500001537

Configuration 1 (start position)

Configuration angle

Configuration 2

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

225

5 Programming and testing

5.9.5 LoadIdentify, load identification service routine

Continued

LoadIdentify with arm loads mounted

The best way to perform load identification is to use 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

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 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, the total weight and center of gravity have to be calculated.

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 is minimized.

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.

• The upper arm load is defined, if the tool 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%.

Continues on next page

226 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.5 LoadIdentify, load identification service routine

Continued

• 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.

• The tool load is known (run LoadIdentify for the tool first).

• The upper arm load is defined, if the payload 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.

Note that LoadIdentify cannot be used for load0

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.

Tip

Always run load identification with cold motors (no warm-up).

Action Information

Start LoadIdentify from the Program Editor . Press the three-position enabling device and then press the Start button on the FlexPendant.

How to start service routines is described in

Load diagram check on page 228

Tap OK to confirm that current path will be cleared and that the program pointer will be lost.

Tap Cancel and then Cancel

Call Rout to quit the service routine without loosing the program pointer.

Tap Tool or Payload .

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 three-position enabling device and select the correct tool/payload in the Jogging menu. Then return to Load-

Identify, press the three-position enabling device, and press Start. Tap Retry and confirm that the new tool/payload is correct.

When identifying tool loads, confirm that the tool is active.

When identifying payloads, confirm that the payload’s tool is active and calibrated.

See

step 4 .

Continues on next page

227 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.5 LoadIdentify, load identification service routine

Continued

Action Information

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.

See

step 4 .

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 +30 or -30 degrees.

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.

Axis 1 to 3 must not be more than 10 degrees from proposed position.

The robot can go through the load identification movements slowly before performing the load identification

(slow test). 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.

Note

If the load identification is planned to be run in manual full speed, then the slow test is required before the actual measurement can start.

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.

When the identification is finished, switch back to manual mode, press the three-position enabling device and the Start button. Tap OK to confirm.

The result of the load identification is now presented on the FlexPendant.

For robots that support the Load diagram check functionality, there is a message if the load is approved or not, and an Analyze button to view more information.

See

Tap Yes to update the selected tool or payload with the identified parameters.

Tap No to exit LoadIdentify without saving the parameters.

Load diagram check

For robots that support the Load diagram check functionality, the combination of the arm load, tool and payload, will be assessed against the load diagram. The ratings of total handling weight as well as of the center of gravity distance to the load diagram in Z and L directions will be provided both for wrist-up and wrist-down configurations.

Continues on next page

228 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.5 LoadIdentify, load identification service routine

Continued

There is a message if the load is approved or not, and an Analyze button to view more information.

• Load approved

• Load not approved

• Load approved only with wrist down

Running LoadIdentify with ModalPayLoadMode deactivated

When the system parameter ModalPayLoadMode is deactivated, set to 0,

LoadIdentify will identify the tool load and the total load. It is no longer possible to define the payload.

With ModalPayLoadMode deactivated it is possible to use the

\TLoad argument in movement instructions. The \TLoad argument describes the total load used in the movement. The total load is the tool load together with the payload that the tool is carrying. If the \TLoad argument is used, then the loaddata in the current tooldata is not considered. For more information about ModalPayLoadMode in movement instructions, see the section MoveL in Technical reference manual - RAPID Instructions, Functions and Data types .

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.

Tip

Always run load identification with cold motors (no warm-up).

Action Information

Start LoadIdentify from the Program Editor . Press the three-position enabling device and then press the Start button on the FlexPendant.

How to start service routines is described in

Editing the tool data on page 184

Tap OK to confirm that current path will be cleared and that the program pointer will be lost.

Tap Cancel and then Cancel

Call Rout to quit the service routine without loosing the program pointer.

Tap OK to continue with the LoadIdentify process.

The selection to update the tool load or the total load is done at a later stage.

Tap OK to confirm that the correct tool and/or total load is active in the jogging menu and that the tool load/total load is correctly mounted.

If it is not correct, release the three-position enabling device and select the correct tool/payload in the Jogging menu. Then return to Load-

Identify, press the three-position enabling device, and press Start. Tap Retry and confirm that the new tool/payload is correct.

When identifying tool loads, confirm that the tool is active.

See

step 4 .

Continues on next page

229 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.5 LoadIdentify, load identification service routine

Continued

Action

Select identification method. If you select the method where the mass is assumed to be known, remember that the tool/total load 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 +30 or -30 degrees.

Information

If the robot is not in correct position for load identification, you are 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.

Axis 1 to 3 must not be more than 10 degrees from proposed position.

The robot can go through the load identification movements slowly before performing the load identification

(slow test). 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.

Note

If the load identification is planned to be run in manual full speed, then the slow test is required before the actual measurement can start.

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.

When the identification is finished, switch back to manual mode, press the three-position enabling device and the Start button. Tap OK to confirm.

The result of the load identification is now presented on the FlexPendant. Tap Tool if you want to update the selected tool, tap Loaddata if you want to update the total load, or tap No if you want to quit without saving.

If Loaddata is selected it is possible to update the total load to either an existing or a new loaddata persistent variable.

Error handling

If the three-position enabling device is released during the load identification (before the movements start), the routine can always be restarted by pressing the three-position 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.

Continues on next page

230 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.5 LoadIdentify, load identification service routine

Continued

Limitations for LoadIdentify

Only tool loads and payloads can be identified with LoadIdentify. Thus arm loads cannot be identified.

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. Confirm the error and press Start to automatically restart.

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.

The load identification ends with an EXIT instruction. That means that the program pointer is lost and must be set to main before starting any program execution.

Tip

The tool and/or payload data can be set manually if the load is small (10% or less of the maximum load) or symmetrical, for example if the tool load is symmetrical around axis 6.

Tip

If the mass of the tool or payload is unknown, the service routine LoadIdentify can in some cases identify a 0 kg mass. If the load is very small compared to the maximum load for the robot, then a 0 kg mass can be ok. Otherwise, try the following to identify the mass.

• Check that the arm loads are correctly defined and redo the identification.

• Find the weight of the load in some other way and perform a load identification with known mass to remove the dependency on arm loads.

LoadIdentify for 4-axis robots

When running LoadIdentify on a robot with 4 instead of 6 axes, there are some differences. In this description of the differences the robot type is assumed to be similar to IRB 260, IRB 460, IRB 660, IRB 760, or IRB 910SC.

The main differences are:

• The used axes are:

1 (or 2 for some robot models)

3 (for all robot models)

6 (or 4 for some robot models)

• Because the first axis (axis 1 or 2) is used, the resulting movements can be large.

• Not all load parameters can be identified.

The first axis (axis 1 or 2) will move approximately ±23 degrees from its current position. Therefore, the load can move a large distance during the identification.

Axes 3 and 6 (or 4) will move as for 6-axis robots. The configuration angle for axis

6 (or 4) works exactly as for 6-axis robots.

Continues on next page

231 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.5 LoadIdentify, load identification service routine

Continued

Because there is not 6 axes, a 4-axis robot cannot identify all parameters of the load. The following parameters cannot be identified:

• I x

- The inertia around the x-axis.

• I y

- The inertia around the y-axis.

• m z

- The z-coordinate for the center of mass.

However, for this type of robot the above parameters have negligible effect on the motion performance. See the definition of the load coordinate system in the following figure.

xx0900000021

Tip

It is possible that the identification procedure fails to estimate the center of gravity if the measured torque data has too high variance. If this happens, it should still be possible to get good results by running the LoadIdentify routine again, preferably with another position of the last axis.

Related information

It is also possible to include LoadIdentify in a program by using RAPID instructions.

See LoadID in Technical reference manual - RAPID Instructions, Functions and

Data types .

How to enter the data manually is described in

, and

Editing the payload data on page 202

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, see Product manual - IRBP /D2009 .

How to define the system parameters for arm loads is described in Technical reference manual - System parameters .

232 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.6 Brake check service routine

5.9.6 Brake check service routine

Overview

The

BrakeCheck service routine is used to verify whether the mechanical brakes work correctly.

The BrakeCheck service routine is included in the RobotWare installation if the controller does not have SafeMove or EPS option.

Note

If the controller has SafeMove or EPS option, the RobotWare installation includes

Cyclic Brake Check service routine. For more details, see Application manual - Functional safety and SafeMove2 .

While running the BrakeCheck service routine the brakes are tested in consecutive order and each test takes 10-15 seconds.

Prerequisites for running the BrakeCheck service routine

Following are the prerequisites for running the

BrakeCheck service routine:

• The robot and all additional axes must be moved to a safe and relaxed position (away from people, equipment and not too much stretched) before performing a brake check. Normally the robot moves only a few centimeters during the brake check.

• Move the robot to a stop point before performing a brake check.

• The brake check can be performed only at normal execution level (not from a trap routine, error handler, event routine, or store path level).

Exclude individual axes from the brake check

It is possible to exclude individual axes from the brake check. For this, set the value of system parameter

Deactivate Cyclic Brake Check for axis to

On. For more details, see

Configure system parameters on page 239

Running the brake check

Following are the two ways to initiate a BrakeCheck service routine:

• Call the

BrakeCheck service routine from FlexPendant. The controller must be in manual mode.

• Call the procedure BrakeCheck from the RAPID program.

WARNING

While the brake check routine is active, do not change the speed from the

FlexPendant and do not use the instructions

VelSet

AccSet

SpeedRefresh

, or any other instruction that affects the motion performance in TRAPS or event routines.

Continues on next page

233 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.6 Brake check service routine

Continued

Note

The RAPID function IsBrakeCheckActive can be used to check if BrakeCheck is active.

Interrupt the brake check

It is not recommended, but it is possible to stop the execution while running a brake check.

If the brake check is interrupted, it will be resumed when the program execution starts again. The brake check can be resumed up to 3 times.

Brake maintenance

Brake maintenance is a feature in the brake check functionality.

The BrakeCheck routine automatically detects if maintenance of the mechanical brakes is needed and activates the Brake maintenance functionality during execution.

Brake maintenance applies the brake and turns the motor shaft 1 radian five times, which gives a movement of the robot arm of less than 1 degree.

There are event logs that tell if Brake maintenance is needed, and if it has been run.

For more information see parameter Brake Maintenance , type General Rapid , topic

Controller , in Technical reference manual - System parameters .

Event logs

When BrakeCheck is executed, the following event logs will be shown:

Event log

10272

10273

Title

Brake Check Done

Brake Check Started

If there is a problem with one or several mechanical brakes, an event log that is describing which mechanical unit and which axis that has bad brakes will be shown:

Event log

37234

37235

Title

Brake Performance Warning

Brake Performance Error

Brake check for MultiMove systems

Note

Make sure that all mechanical units are standing still before ordering a

BrakeCheck

One of the motion tasks call the routine BrakeCheck to perform brake check for all mechanical units in all tasks.

The brake check must not be performed while any tasks are in synchronized mode

(coordinated movement). It is necessary to synchronize all motion tasks with

Continues on next page

234 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.6 Brake check service routine

Continued

WaitSyncTask instructions before and after the actual brake check. If running a movement instruction when one motion task is execution a BrakeCheck , you will have an error (41888) and all execution will stop. Instruction

ExitCycle is also forbidden to use during an active BrakeCheck .

The RAPID function IsBrakeCheckActive can be used to check if there is an ongoing

BrakeCheck

Only one call to BrakeCheck can be done at a time. This is checked by the service routine and if more than one RAPID task or client try to execute the routine, you will have an error (41886).

Program example

T_ROB1

PERS tasks task_list{2} := [ ["T_ROB1"], ["T_ROB2"] ];

VAR syncident sync1;

VAR syncident sync2;

...

IF PLC_di1_DO_CBC = 1 THEN

WaitSyncTask sync1, task_list;

BrakeCheck;

WaitSyncTask sync2, task_list;

ENDIF

T_ROB2

PERS tasks task_list{2} := [ ["T_ROB1"], ["T_ROB2"] ];

VAR syncident sync1;

VAR syncident sync2;

...

IF PLC_di1_DO_CBC = 1 THEN

WaitSyncTask sync1, task_list;

! Wait for T_ROB1 to be ready with BrakeCheck

WaitSyncTask sync2, task_list;

ENDIF

Brake check on additional axes

To be able to run brake check on additional axes, the parameter Max Static Arm

Torque (in topic Motion and type Brake ) needs to be calculated for the additional axis and entered into the configuration. Brake check uses this value when testing the brake at error-level.

The parameter should be the maximum static torque that the brake needs to withstand when the additional axis is positioned in maximum gravity. The following formula should be used:

Max Static Arm Torque = (M*L*g)/n

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

235

5 Programming and testing

5.9.6 Brake check service routine

Continued

Length to mass (L)

Mass (M) * Gravity constant (g)

Transmission (n)

Motor (1)

Gearbox (2)

Arm (3)

M * g xx1600001289

To calculate the parameter for an axis that has no gravity, for example a track, the below formula may be used:

Max Static Arm Torque = Tbrake min/1.35

Tbrake min for ABB motor units can be found in the product specification for the specific motor unit, see Product specification - Motor Units and Gear Units .

For more information about parameter Max Static Arm Torque , see topic Motion , type Brake in Technical reference manual - System parameters .

Note

Note that the calculated value should be entered in [Nm] and calculated to the motor side.

Description of the I/O setup

Signal configuration

It is possible to configure digital output signals that reflect the status of the mechanical brakes in an open RAPID module. The digital output signals that can be configured are OK , WARNING , ERROR , and ACT (brake check active) for each drive module.

The signal configuration should be done in the RAPID module BC_config_IO.sys

, see

Description of the I/O setup on page 236 .

The file BC_config_IO.sys

can be found in directory hd0a\<active system>\PRODUCTS\RobotWare_6.0x.xxxx\utility/BrakeCheck , and must then be copied to the HOME directory of the active system.

Note

Remember to update the I/O configuration with the digital output signals.

In a MultiMove system you need to define an OK , WARNING , ERROR , and ACT digital output signals for each drive module.

Note

Continues on next page

236

If the signals should keep their values after a power fail, the power fail settings in the system parameters must also be updated, see

Description of the I/O setup on page 236 .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.6 Brake check service routine

Continued

Description of the BC_config_IO module

MODULE BC_config_IO(SYSMODULE,NOVIEW)

PROC BC_config_IO_proc(VAR string user_io_names{*,*})

!TPWrite "BC_config_IO_proc";

! Define your own signals. The signal

! names must be signals defined in EIO.cfg

! If 1 drive module user_io_names{1, 1}:="BCACT1"; user_io_names{1, 2}:="BCOK1"; user_io_names{1, 3}:="BCWAR1"; user_io_names{1, 4}:="BCERR1";

! If 2 drive modules

!user_io_names{2, 1}:="BCACT2";

!user_io_names{2, 2}:="BCOK2";

!user_io_names{2, 3}:="BCWAR2";

!user_io_names{2, 4}:="BCERR2";

! If 3 drive modules

!user_io_names{3, 1}:="BCACT3";

!user_io_names{3, 2}:="BCOK3";

!user_io_names{3, 3}:="BCWAR3";

!user_io_names{3, 4}:="BCERR3";

! If 4 drive modules

!user_io_names{4, 1}:="BCACT4";

!user_io_names{4, 2}:="BCOK4";

!user_io_names{4, 3}:="BCWAR4";

!user_io_names{4, 4}:="BCERR4";

ENDPROC

ENDMODULE

Description of the EIO.cfg file

EIO:CFG_1.0:6:1::

...

EIO_SIGNAL:

-Name "BCACT1" -SignalType "DO"

-Name "BCOK1" -SignalType "DO"

-Name "BCWAR1" -SignalType "DO"

-Name "BCERR1" -SignalType "DO"

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

237

5 Programming and testing

5.9.6 Brake check service routine

Continued

Brake check signal description

Introduction

Description of different signal states for brake check in the BrakeCheck routine.

The signal names are according to

Description of the I/O setup on page 236 .

Timing sequence for brake check signals

Description of which signals are set at different times during the BrakeCheck execution.

Beginning of brake check

The following signals are set in the beginning of the BrakeCheck execution.

Signal

BCOK

BCACT

BCERR

BCWAR

Set to

End of brake check

The following signals are set in the end of the BrakeCheck execution.

Signal

BCOK

BCERR

BCWAR

BCACT

BrakeCheck test OK

Set to

BrakeCheck test

WARNING

Set to

1 0

BrakeCheck test ER-

ROR

Set to

Program Pointer moved to Main after interrupted brake check

When the program pointer is moved to Main after an interrupted

BrakeCheck execution, the following signals are set.

Signal

BCOK

BCACT

Set to

During the first brake check test

Signal

BCOK

BCERR

BCWAR

BCACT

Signal state

Interrupted brake check test, program pointer still in BrakeCheck routine

Signal

BCOK

Signal state

Continues on next page

238 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

5 Programming and testing

5.9.6 Brake check service routine

Continued

Signal

BCERR

BCWAR

BCACT

Signal state

Interrupted brake check test, program pointer moved from BrakeCheck routine

Signal

BCOK

BCERR

BCWAR

BCACT

Signal state

Configure system parameters

About the system parameters

The configuration of system parameters required for a robot system should be made before running the brake check.

Note

It is required to restart the IRC5 controller after changing system parameters.

Type Mechanical Unit

All mechanical units for additional axes that shall be supervised must have the parameters Activate at Start Up and Deactivation Forbidden set to On. (Supervised mechanical units must always be active.)

Type Arm

If an axis should be excluded from brake check, set the parameter Deactivate

Cyclic Brake Check for axis to On.

Type Brake

If brake check is executed on an additional axis, a lowest safe brake torque must be defined. A 5% margin is added during the test for setting the fail limit. The parameter used is Max Static Arm Torque defined in on motor side. A warning limit is set with a higher torque value (depending on the brake).

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

239

This page is intentionally left blank

6 Running in production

6.1.1 Starting programs

6 Running in production

6.1 Basic procedures

6.1.1 Starting programs

Starting programs

Use this procedure to start a program for the first time or to continue running a program that has been stopped.

If your robot system has the option Multitasking installed, also see

Using multitasking programs on page 245

Action

Check that all necessary preparations are done to the robot and in the robot cell and that no obstacles exist within the robot work area.

Information

Make sure no personnel are inside the robot cell.

Select operating mode on the controller with the mode switch.

6 xx0600002782

C: Motors on button

D: Mode switch

Press the Motors on button on the controller to activate the robot.

Is a program loaded?

If yes, proceed to the next step.

If no, load a program.

How to load programs is described in section

Quickset menu, Run Mode on page 85

If needed, select run mode and speed using the Quickset menu.

See

and

Quickset menu, Speed on page 87 .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

241

6 Running in production

6.1.1 Starting programs

Continued

Action Information

In Auto mode:

1 Press the Start button on the Flex-

Pendant to start the program.

In manual mode:

1 Select start mode.

2 Press and hold the three-position enabling device.

3 Press the Start button on the Flex-

Pendant to start the program.

Is the Regain Request dialog box displayed?

If yes, return the robot to the path using a suitable method.

If no, proceed.

The button is shown in the section

Hard buttons on page 39

How to select start mode is detailed in section

Using the hold-to-run function on page 211 .

Returning the robot to the path is described in section

Returning the robot to the path on page 254

If the Cursor does not coincide with PP dialog box is displayed then tap PP or

Cursor to select from where the program should start. Then press the Start button again.

This dialog box is only displayed if the system parameters of type Warning at start are defined. See Technical reference manual - System parameters .

Continue running after the program is changed

You can 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 current robot 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

Restart from the beginning

A program can be restarted from the Production Window or the Program Editor .

PP to Main from the Production Window will reset the program pointer to the production entry in all normal tasks, including tasks deactivated in the task selection panel.

PP to Main from the Program Editor will reset the program pointer to the production entry in the specified task only, even if the task is deactivated in the task selection panel.

Use this procedure to restart a program from the Production Window .

Action

On the ABB menu, tap Production Window .

Tap PP to Main .

Start the program by pressing the Start button on the FlexPendant.

Continues on next page

242

Use this procedure to restart a program from the Program Editor .

Action

On the ABB menu, tap Program Editor .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Limitations

6 Running in production

6.1.1 Starting programs

Continued

Action

Tap Debug .

Tap PP to Main .

Start the program by pressing the Start button on the FlexPendant.

Only one program at a time can be executed, unless your system has the

Multitasking option. If so several programs can be executed simultaneously. See how to select tasks in

Quickset menu, Tasks on page 88

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.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

243

6 Running in production

6.1.2 Stopping programs

6.1.2 Stopping programs

Stopping programs

If your robot system has the Multitasking option installed, see

Using multitasking programs on page 245

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 hardware button set of the jogging device.

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

Step-by-step mode

Action

Release the Start button

Information

The hold-to-run function is described in section

The

FlexPendant on page 37

The robot will stop after executing each instruction.

Execute the next instruction by pressing the Forward button again.

The STOP and Forward button are described in section

The FlexPendant on page 37 .

If you press the STOP button while executing a move instruction, the robot will stop without completing the move.

244 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.1.3 Using multitasking programs

6.1.3 Using multitasking programs

Overview

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 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

In a system with the option Multitasking installed, you may have one or several programs running in parallel, for instance in a MultiMove cell with more than one robot where each robot has its own task and program (multitasking).

For general information on program handling, see

Loading an existing program on page 151

Multitasking is described in Application manual - Controller software IRC5 .

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.

To be able to step, start and stop a Static or Semistatic task: set Task Panel

Settings to All tasks and activate the task using the Quickset menu. See Application manual - Controller software IRC5 , section Multitasking .

The concepts of Static, Semistatic, and Normal are described in Technical reference manual - System parameters , type Tasks .

Load, run, and stop multitasking programs

This section describes how to load, run, and stop multitasking programs.

Action

Make sure there is more than one task set up. This is done using system parameters, see Technical reference manual - System parameters .

Load programs to respective task using the Program Editor or the Production Window , this is described in section

If one or more task should be disabled, go to the Quickset menu to do this. See section

Quickset menu, Tasks on page 88

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.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

245

6 Running in production

6.1.3 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.

Load a program from the Production Window

Action

On the ABB menu, tap Production Window .

Tap the task into which you want to load a program.

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 56 .

The file dialog box appears.

Tap the program you want to load followed by OK .

Load a program from the Program Editor

Action

On the ABB menu, 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 56 .

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. To edit static and semistatic tasks, see Application manual - Controller software IRC5 , section Multitasking .

246 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.1.4 Using motion supervision and non motion execution

6.1.4 Using motion supervision and non motion execution

Motion supervision

The controller software has functionality aiming at reducing collision impact forces on the robot. This helps protecting the robot and external equipment from severe damage if a collision occurs.

Motion supervision during program execution is by default always active, regardless which options are installed in the controller. When a collision is detected, the robot will immediately stop and relieve the residual forces by moving in reversed direction a short distance along its path. The program execution will stop with an error message. The robot remains in the state Motors on so that program execution can be resumed after the collision error message has been acknowledged.

Moreover, there is a software option called Collision Detection , which has extra features such as supervision during jogging. To find out if your system has this option installed, tap System Info on the ABB menu. Expand the node System

Properties and tap Options under Control Module .

Functions in RobotWare base

Description of functions in RobotWare base:

• Path Supervision in automatic and manual full speed mode used to prevent mechanical damage due to the robot running into an obstacle during program execution.

• Non motion execution used to run a program without robot motion.

Functions in Collision Detection

A RobotWare system with Collision Detection has additional functionality:

• Path Supervision in manual mode and the possibility to tune supervision in all modes.

• Jog Supervision used to prevent mechanical damage to the robot during jogging.

• RAPID instruction

MotionSup used to activate/deactivate collision detection and to tune sensitivity during program execution.

Note

All motion supervision must be set for each task separately.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

247

6 Running in production

6.1.4 Using motion supervision and non motion execution

Continued

Editing motion supervision settings

This section describes how to modify settings for motion supervision.

Action

On the ABB menu tap Control Panel and then

Supervision .

Information

Tap the Task list and select a task.

If you have more than one task, you need to set the desired values for each task separately.

Tap OFF/ON to remove or activate path supervision.

Tap the 123...

button to open the soft number pad and type a value to adjust the sensitivity of path supervision.

Tip

Note

Sensitivity can be set between

0 and 300. If it is set lower than

80, however, the robot may stop due to internal drag.

If the option Collision Detection is not installed,

• sensitivity setting will have no effect.

• path supervision affects only the robot in auto and manual full speed mode.

Note

You can modify the sensitivity of

Path supervision . For more information, see

Setting sensitivity of Motion Supervision on page 249 .

4 Tap OFF/ON to remove or activate jog supervision.

Tap the 123...

button to open the soft number pad and type a value to adjust the sensitivity of jog supervision.

Note

Tip

Sensitivity can be set between

0 and 300. If it is set lower than

80, however, the robot may stop due to internal drag.

If the option Collision Detection is not installed, these settings will have no effect.

Note

You can modify the sensitivity of

Path supervision . For more information, see

Setting sensitivity of Motion Supervision on page 249

5 Under Execution Settings , tap OFF/ON to deactivate or activate non motion execution. This is a separate function, not a part of motion supervision.

See

Non motion execution on page 249

for information about this function.

Continues on next page

248 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.1.4 Using motion supervision and non motion execution

Continued

Setting sensitivity of Motion Supervision

Use the following procedure to set the sensitivity of Path Supervision and Jog

Supervision .

Action

On the ABB menu, tap Control Panel and then

Configuration .

Information

Tap Topics and select Motion .

Select the type Motion Supervision and tap.

Select one from the list and tap Edit .

For example: rob1

Select Path Collision Detection Level , tap twice and set a value.

The maximum value that can be set is 500.

Click OK .

Select Jog Collision Detection Level , tap twice and set a value.

The maximum value that can be set is 500

Click OK .

Non motion execution

Non motion execution enables you to run a RAPID program without robot motion.

All other functions work normally; current cycle times, I/O, TCP speed calculation and so on.

Non motion execution can be used for program debugging or cycle time evaluation.

It also represents a solution if you need to measure for example glue or paint consumption during a cycle.

When non motion execution is activated it can be executed in:

• manual mode

• manual full speed mode

• auto mode

Cycle times will be simulated according to the selected mode.

Note

Non motion execution can only be activated when the system is in Motors Off state.

CAUTION

Non motion execution is reset after a reboot. If you intend to run the program in non motion mode, do not restart without checking the status of Non motion execution . Starting the program incorrectly may cause serious injury or death, or damage the robot or other equipment.

Related information

For more information on Collision Detection , see Application manual - Controller software IRC5 .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

249

6 Running in production

6.1.5 Using the hot plug option

6.1.5 Using the hot plug option

Hot plug option

The hot plug option makes it possible to:

• Disconnect the jogging device from a system in automatic mode and thereby run the system without a jogging device connected.

• Temporarily connect and operate a jogging device without interrupting the application running on the system.

WARNING

Pressing the hot plug button disables the emergency stop button on the

FlexPendant. Only press the hot plug button while connecting or disconnecting the FlexPendant.

WARNING

A disconnected FlexPendant must always be stored separated from the IRC5 controller!

Connect and disconnect the FlexPendant using the hot plug button

The following procedure describes how to connect or disconnect the FlexPendant on a system in automatic mode using the hot plug button option.

Note

Do not switch to manual mode (or manual full speed mode) while the system is running without the FlexPendant. The FlexPendant must be connected when you switch to automatic mode otherwise you cannot confirm the mode change.

Action Information

Make sure that the system is in automatic mode.

Press and hold the hot plug button.

A red lamp inside the button indicates when pressed.

Continues on next page

250 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.1.5 Using the hot plug option

Continued

Action

Keep pressing the hot plug button and at the same time, switch the jumper plug with the FlexPendant plug.

Information xx0600002784

A: Hot plug button

B: FlexPendant connector

4 Release the hot plug button.

xx0600002796

Jumper plug

Make sure that the button is not stuck in the actuated position since this disables the FlexPendant emergency stop button.

Note

When the FlexPendant is disconnected, the jumper plug must be connected in its place.

Note

If the hot plug button is released while neither the jumper plug, nor the

FlexPendant is connected, the robot movements will be stopped since the emergency stop chains are opened.

Limitations for messages on the FlexPendant

When using the hot plug option, the following limitations apply to messages on the FlexPendant:

Operator messages

Some applications may require input from the operator by using the FlexPendant

(e.g. applications using RAPID instructions TPReadNum , UIMsgBox , etc.). If the application encounters such an operator message, program execution will wait.

After connecting the FlexPendant you must then stop and start the program execution to be able to see and respond to these messages. They are not displayed automatically by just connecting the FlexPendant.

If possible, avoid using these types of instructions when programming systems that are using the hot plug button option.

Continues on next page

251 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.1.5 Using the hot plug option

Continued

Event log messages

When connecting the FlexPendant, event log messages can be viewed also for the period when the FlexPendant was disconnected, since these are stored on the controller.

252 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.2.1 General procedure when troubleshooting

6.2 Troubleshooting and error recovery

6.2.1 General procedure when troubleshooting

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 Operating manual - Troubleshooting IRC5 .

• Faults NOT detected by the built-in diagnostics system. These faults are described in section Other types of faults in Operating manual - Troubleshooting IRC5 .

Faults causing error message on the FlexPendant

The control system is supplied with diagnostic software to facilitate troubleshooting 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 troubleshooting, it is important that some basic principles are followed.

These are specified in troubleshooting principles in Operating manual - Troubleshooting 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 Operating manual - Troubleshooting IRC5 .

To troubleshoot faults NOT causing error messages on the FlexPendant, follow steps 3 and 4 in the procedure above.

Other possible actions

Some errors may require running a service routine. See section

Service routines on page 217 .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

253

6 Running in production

6.2.2 Returning the robot to the path

6.2.2 Returning the robot to the path

About paths and return regions

While a program is running, 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 . If the robot is stopped by an emergency or safety stop it may also 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 program execution.

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 , type Path Return Region .

Returning to path

Turning off the power to the robot 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 choose 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.

For more information see Technical reference manual - System parameters , section

Topic Controller Type Path Return Region .

Action

Make sure there are no obstacles blocking the way and that payload and 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 motors.

Press the Start button on the FlexPendant to continue execution from where it stopped.

One of these things will happen:

• The robot or axis will slowly return to the path and execution will continue.

• The Regain Request dialog will be displayed.

If the Regain Request dialog is displayed, select the proper action.

Select action

If you...

then tap...

want to return to the path and continue the program

Yes want to return to the next target position and continue the program

Continues on next page

254 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

If you...

don't want to continue the program

6 Running in production

6.2.2 Returning the robot to the path

Continued then tap...

Cancel

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

255

6 Running in production

6.2.3 Running RAPID program with uncalibrated mechanical unit

6.2.3 Running RAPID program with uncalibrated mechanical unit

When is this useful?

If a servo gun is damaged or uncalibrated, you may want to run a service routine.

In order to run the service routine (or any RAPID code), even though an additional axis is uncalibrated, the steps in this description must be followed.

How to get the program started

Action

Set the system parameter Active at Start Up (in type Mechanical Unit , topic Motion ) to No.

Set the system parameter Disconnect at Deactivate (in type Measurement Channel , topic Motion ) to Yes.

If any of the system parameter values are changed, restart the controller.

Deactivate the uncalibrated mechanical unit.

Move the program pointer to Main (otherwise the mechanical unit will be automatically activated).

Run the service routine or other RAPID code.

256 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.3.1 Present operating mode

6.3 Operating modes

6.3.1 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

Two position mode switch

Three position mode switch

Automatic mode

Manual reduced speed mode

Manual full speed mode

Action Information

To switch from manual to automatic mode detailed in

Switching from manual to automatic mode on page 259

To switch from automatic to manual mode detailed in

Switching from automatic to manual mode on page 261 .

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

A Operator window

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

257

6 Running in production

6.3.1 Present operating mode

Continued

Operating mode

Active system

Controller state

Program state

Mechanical units, active is highlighted

Related information

About the automatic mode on page 27

About the manual mode on page 29

258 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.3.2 Switching from manual to automatic mode

6.3.2 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

Action

Set the mode switch in the automatic position.

A mode change dialog is displayed.

Information xx0300000467

If any debug settings have been changed, a dialog informs about the changes and if these values will be reset. Tap Acknowledge .

If these values are reset or not is defined by system parameters in the type Auto Condition

Reset in the topic Controller .

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 241

Note

If your specific system uses a distributed operator’s panel, controls and indicators may not be placed exactly as described in this manual. 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.

Continues on next page

259 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.3.2 Switching from manual to automatic mode

Continued

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.

Related information

A number of conditions can be set or reset when switching to automatic mode, see Technical reference manual - System parameters , sections Auto Condition

Reset and Run Mode Settings .

260 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.3.3 Switching from automatic to manual mode

6.3.3 Switching from automatic to manual mode

Switching from automatic to manual mode

Action

Set the mode switch in the manual position.

Information

2 xx0300000468

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 Operating manual - Troubleshooting IRC5 .

Note

If your specific system uses a distributed operator’s 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.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

261

6 Running in production

6.3.4 Switching to manual full speed mode

6.3.4 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

Action

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.

Information

Error handling is detailed in Operating manual - Troubleshooting IRC5 .

Note

When you switch to manual full speed mode, all the functionality except for Start ,

Stop , and Step are disabled.

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 switch back to the previous mode the dialog is closed automatically and there is no change in the mode.

262 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.4.1 Modifying and tuning positions

6.4 Modifying positions

6.4.1 Modifying and tuning positions

Overview

Positions are instances of the data type robtarget or jointtarget. See Technical reference manual - RAPID Instructions, Functions and Data types .

The positions can be tuned using the function HotEdit, where you enter offset values using a soft keyboard.The offset value is used together with the original position value. See

Tuning positions with HotEdit on page 268

. The HotEdit menu is described in section

HotEdit menu on page 54 .

The positions can also be modified using the Modify positions function in the

Program Editor or the Production Window where you step and jog the robot to the new position. A modified position value overwrites the original value. See

Modifying positions in the Program Editor or Production Window on page 264 .

CAUTION

Changing programmed positions may significantly alter the robot’s movement pattern.

Always make sure any changes are safe for both equipment and personnel.

Positions in arrays

If a position is declared as an array, then the procedure for modifying or tuning may differ slightly depending on how the array is indexed in the move instruction.

Limitations

Note that jointtargets can only be modified using the Modify positions method in the Program Editor and the Production Window , i.e. not with HotEdit.

Note

Your system can have restrictions on how positions can be modified. Restrictions can apply to distance using system parameters (topic Controller , type ModPos

Settings ) and which positions can be modified using UAS.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

263

6 Running in production

6.4.2 Modifying positions in the Program Editor or Production Window

Overview

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 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.

Prerequisites

To modify positions using the Program Editor or Production Window.

• the system must be in manual mode

• the target position must have a initial value. For example: CONST robtarget p10:=[[515.00,0.00,712.00],[0.707107,0,0.707107,0],[0,0,0,0],

[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]]; CONST jointtarget jpos10:=[[-0,-0,0,-0,-0,-0],

[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];

Note

To modify positions in the Production Window, you must have started the program so that the motion pointer is set.

Applying modified positions

The modified position values will normally be used when you restart the program.

If the robot cannot use the values directly at start, a warning is displayed. Then the modified position will be used the next time that the position is used in the program.

Modifying positions

This procedure describes how to modify positions, either by single-stepping to the positions or jogging. You can use the Program Editor or the Production Window , the functionality is the same.

Action

On the ABB menu, tap Program Editor .

Stop the program, if running.

Information

Continues on next page

264 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.4.2 Modifying positions in the Program Editor or Production Window

Continued

Action Information

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.

When single-stepping, if the instruction or procedure call has more than one position argument, continue to step to reach each argument.

Jog to the new position.

When using the jogging method, tap to select the position argument you want to change.

In the Program Editor, tap Modify Position .

In the Production Window, tap Debug and then

Modify Position .

A confirmation dialog appears.

When modifying a position in an array that is indexed with a variable you will have to select which element in the array to modify before the modification is executed.

Tap Modify to use the new position, Cancel to keep the original.

If you select the check box Don’t show this dialog again in the confirmation dialog, then you will not get any more confirmation dialogs when modifying positions.

Note

This is only valid for the current Program Editor .

8 Repeat step 3 through 7 for each position argument you want to change.

Limitations

The Modify position button in the Program Editor is disabled until you select a position argument (that is possible to modify).

The Modify position button in the Production Window is disabled until the motion pointer is set and a position is selected. To set the motion pointer, the program must be started and then stopped.

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. The baseline concept is described in section

Tuning positions with HotEdit on page 268 .

If a named position is modified, all other instructions using that position will be affected.

In the Production Window , circle points cannot be modified in synchronized mode.

See Application manual - MultiMove .

Differences between Program Editor and Production Window

The procedure for modifying positions is the same in the Program Editor and the

Production Window . However, there are differences in how positions are selected.

Continues on next page

265 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.4.2 Modifying positions in the Program Editor or Production Window

Continued

Also, if your system uses MultiMove, then the result from the Program Editor and the Production Window will differ. See Application manual - MultiMove .

Program Editor selections

To select a position for modification in the Program Editor , tap the desired position.

Production Window selections

To select a position for modification in the Production Window you must step the program to the desired position.

Note

If you have executed the program from another window and then switch back to the Production Window , the selected position will be changed to the position where the motion pointer now is. Make sure the correct position is selected before making the modification!

Related information

For an overview on how to modify positions, see

Modifying and tuning positions on page 263 .

HotEdit and baseline are described in

Tuning positions with HotEdit on page 268 .

The HotEdit menu is also described in

HotEdit menu on page 54 .

Modifying positions in the Program Data window is described in

Editing data instances on page 171

Technical reference manual - RAPID Instructions, Functions and Data types .

Technical reference manual - System parameters .

Application manual - MultiMove

Examples planned path

The following examples show how the planned path will be effected when modifying positions.

Linear movement

In example A the robot is stopped on path before reaching the position P10. The robot is jogged off path to the new position (P10x) and the position P10 is modified.

In example B the robot is stopped on path in position P10. The robot is jogged off path to the new position (P10x) and the position P10 is modified.

xx0800000175

Continues on next page

266 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.4.2 Modifying positions in the Program Editor or Production Window

Continued

In both examples, when restarting the program the robot continues from the new

P10 (that is now the same as P10x) directly to P20 without returning to the previous planned path (via the old P10).

Circular movement

In this example the robot is stopped on path in position P20 (circle point) and then jogged to the new position P20x. The position P20 is modified.

xx0800000176

In single robot systems or MultiMove systems in unsynchronized mode: When restarting the program the robot continues directly from the new P20 (that is now the same as P20x) to P30 without returning to the previous planned path (via the old P20). The new planned path from P20 (P20x) to P30 is calculated using these two positions and position P10.

In MultiMove synchronized mode: When restarting the program the robot returns to the old P20 and uses the previously planned path to P30. In the next cycle only the new P20 (P20x) is used.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

267

6 Running in production

6.4.3 Tuning positions with HotEdit

6.4.3 Tuning positions with HotEdit

Overview

HotEdit is used to tune programmed positions. This can be done in all operating modes and even while the program is running. Both coordinates and orientation can be tuned.

HotEdit can only be used for named positions of the type robtarget (see limitations below).

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

The HotEdit menu is described in the section

HotEdit menu on page 54 .

Applying tuned positions

Tuning values are used directly by an executing program when you tap Apply . If tuning is done close to the program or motion pointer it may be hard to predict exactly when it will take effect. It is therefore important that you know where in the program the robot is if applying offset values while the program is running.

However, the new values are not stored in the baseline until you use a Commit command.

How to tune positions

This is how you tune programmed positions using HotEdit:

Action

In the Programmed targets window, select the positions to be tuned and add them to Selected targets by tapping the arrow.

Tap Tune Targets and select tuning mode (linear, reorient, or external axes) and then coordinate system (tool or work object).

Tap + and - to specify the exact tuning of the position(s) in x, y and z direction. Select

Increment to define the step size of these buttons.

To activate the new values, tap APPLY . The offset will be used directly if the program is running.

If you are satisfied with the result and want the tuned positions to become part of the baseline, tap Baseline and then Commit Selection .

If, however, the selected targets need further tuning, you can tap Baseline and then

Restore Selection and start all over again, or you can simply continue tuning until you are satisfied.

Working with selections

A selection of positions to be tuned later can be saved on the controller mass memory unit. If your system uses UAS, this may be the only way to select positions for tuning.

The commands for working with selections are located in the File menu:

Save Selection As Make sure that the window Selected targets shows nothing but the positions to be saved. Tap File and Save Selection As . Enter the name and optionally a description of the file, then tap OK .

Continues on next page

268 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.4.3 Tuning positions with HotEdit

Continued

Open Selection

Clear Selection

Tap File and Open Selection . Then tap the selection you want to use and tap OK .

Clear the Selected targets area by tapping File and Clear Selection .

Baseline concept

A baseline can be defined as a reference against which future changes are measured. The baseline concept makes it possible to undo tuning and revert to the position values stored in the latest baseline. To do this you use a Restore command.

When a Commit command is performed the baseline is updated with new offset values, and the old values no longer exist in program memory.

Use the baseline menu to apply or reject tuning.

• Restore Selection will discard all tuning of the currently selected positions and revert them to the values of the latest baseline, meaning that their offset values will be 0,0.

• Restore Entire Program will discard ALL tuning to programmed positions since the latest Commit command. This may include several HotEdit sessions for the same task. If the system uses Absolute Limit ModPos any Modify

Position command from the Program Editor will also be undone.

• Commit Selection will apply the offset of the currently selected positions to the baseline.

• Commit Entire Program will apply ALL tuning to programmed positions. This may include several HotEdit sessions for the same task. If the system uses

Absolute Limit ModPos it also includes Modify Position performed in the

Program Editor.

Baseline target criteria

Targets that fulfil all of the following criteria are part of the baseline:

• The data type must be robtarget or jointtarget

• It must not be declared locally in a routine

• It must not be declared as part of an array of targets

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

269

6 Running in production

6.4.3 Tuning positions with HotEdit

Continued

Illustration of baseline concept

The baseline concept is illustrated below, where a point is moved, restored and committed. Starting out from the original baseline (A), let us assume that you move the point (B) twice. If you regret the changes you perform a restore command (C).

But if you instead continue moving the point and perform a commit command (B

+D), you will have created a new baseline (E) and there is no way to revert to the original baseline. If you move the point one more time and then restore, the point is moved back to the latest baseline (E).

xx0600002620

Original baseline

Move selected point

Restore

Commit

New baseline

Restore Selection or Restore Entire Program

The following example shows the difference between Restore Selection and

Restore Entire Program to original. The same idea applies for Commit Selection and Commit Entire Program .

Action

The robtargets p10 and p30 are added to Selected Targets and tuned once.

p10 is removed from Selected Targets p30 is tuned again.

• Restore Selection sets the currently selected position, p30, to its value in the latest baseline. p10 is not affected, thus still tuned.

• Restore Entire Program sets all tuned positions, that is both p10 and p30 to their baseline values.

HotEdit for external axes

External axes can be tuned with HotEdit if they are activated in at least one of the selected robtargets. Only axes with active values are tuned.

Limitations

HotEdit tuning is only possible for named (e.g. p10, p20) robtargets. (* robtargets are not visible in the treeview.)

If a robtarget is declared as an array, it must be indexed with a number to be modified in HotEdit.

Continues on next page

270 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.4.3 Tuning positions with HotEdit

Continued

It is only possible to perform HotEdit tuning on targets that are part of the baseline.

Targets that are NOT part of the baseline will not be shown in the HotEdit treeview, as they cannot be selected for tuning. This means that a target declared locally in a routine, for example, will not be displayed.

HotEdit tuning is possible for robtargets only. (Jointtargets can only be tuned by using Modify Position in the Program Editor .) If the system uses Absolute limit

ModPos these jointtargets are however part of the baseline and will be affected when Restore Entire Program and Commit Entire Program are used.

Note

For more information about Absolute Limit ModPos , see the Technical reference manual - System parameters , section Topic Controller - Type ModPos Settings .

Using UAS in HotEdit

The user authorization system can be used to restrict the Hot Edit functionality and only allow a user to edit pre-selected positions. These are loaded by tapping

File and then Open Selection . The selected positions can then be tuned in the usual way.

Related information

Technical reference manual - System parameters .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

271

6 Running in production

6.4.4 Working with displacements and offsets

6.4.4 Working with displacements and offsets

About displacements

Sometimes, the same path is to be performed at several places on the same object, or on several work pieces located next to each other. 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.

The displacement coordinate system is described in section

Coordinate systems for jogging on page 123

Select displacement method

Depending on how, when, and how often you want to use displacements, the best method may vary.

Moving a work object

Moving a work object is suitable when you do not need to move or displace the work object very often.

This is detailed in section

Defining the work object coordinate system on page 193 .

Displace a work object

A work object consists of a user frame and a object frame. You can move one or both of these frames. If you move both frames, then the whole work object is moved.

It can be useful to displace the object frame from the user frame for instance when using one fixture for several work objects. Then you can keep the user frame and displace the object frame for the work objects.

See procedure How to define object frame in section

Defining the work object coordinate system on page 193

Displace and rotate a work object

You may want to displace and rotate the object frame from the user frame if the displacement is not in just x, y, and z.

To displace in x, y, and z, you can use the same method as above. To rotate the work object, follow the procedure in section

Editing the work object data on page 197 .

About offsets

Sometimes it is easier to define a position as an offset from a given position. If, for example, you know the exact dimensions of a work object, it will only be necessary to jog to one position.

The offset is programmed with the displacement distance in x, y, and z direction, in relation to the work object. For instance:

MoveL Offs(p10, 100, 50, 0), v50...

Define the offset for the position with the following expressions:

1 Original position / starting point

Continues on next page

272 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

6 Running in production

6.4.4 Working with displacements and offsets

Continued

2 Displacement in x direction

3 Displacement in y direction

4 Displacement in z direction

Examples

This example shows the move instructions with offsets to move the robot in a square (clockwise), starting at p10, with a 100 mm displacement in x and y.

MoveL p10, v50...

MoveL Offs(p10, 100, 0, 0), v50...

MoveL Offs(p10, 100, 100, 0), v50...

MoveL Offs(p10, 0, 100, 0), v50...

MoveL p10, v50...

How to create position offsets

This procedure details how to change a position to become an offset position.

Action

In the Program Editor, tap to select the position argument to edit.

Information

Tap Edit and then Change Selected .

Tap Functions and then Offs .

Tap to select each expression, <EXP> , and then tap any of the desired available data or functions.

You can also tap Edit to access more functions. Tap All to open the soft keyboard and edit all expressions at the same time, or tap Only Selected to edit one at a time with the soft keyboard.

You can use the filter to narrow down the available data. You can also change data type of the available data.

Tap OK to save changes.

Related information

There are a number of functions in RAPID that may be useful. See Technical reference manual - RAPID Instructions, Functions and Data types , and Technical reference manual - RAPID Overview .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

273

6 Running in production

6.4.5 Moving the robot to a programmed position

6.4.5 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.

Action

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.

Information

If you have many programmed positions you can use a filter to narrow down the visible positions. See section

Filtering data on page 93 .

Press and hold the three-position 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.

274 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

7 Handling inputs and outputs, I/O

7.1 Viewing signal lists

7 Handling inputs and outputs, I/O

7.1 Viewing signal lists

Overview

I/O signal properties is used to view the input and output signals and their values.

Signals are configured with system parameters .

How to view signal lists

This section details how to view a list of signals.

Action

On the ABB menu tap Inputs and Outputs .

The list of Most Common I/O signals is displayed.

en0400000770

2 Tap View to change the selection of signals in the list.

Tip

Tap the Select Layout menu if you want to view signal labels in the list.

Related information

Simulating and changing signal values on page 276 .

Filtering data on page 93

Configuring Most Common I/O on page 114

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

275

7 Handling inputs and outputs, I/O

7.2 Simulating and changing signal values

7.2 Simulating and changing signal values

Simulating and changing signal values

A signal can be changed into a simulated signal. The value of the signal can also be changed.

Use the following procedure to simulate a signal or to change the value of a signal:

Action

On the ABB menu, tap Inputs and Outputs .

A list of most common signals is displayed. See section

Configuring Most Common

I/O on page 114 .

Tap View and select a signal filter.

The signal list is updated.

xx1700002252

Note

Tap All Signals to view all the signals.

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.

Note

When you remove the simulation from a signal, the signal value returns to the same value it had before it was simulated. Also the cross connections are updated accordingly.

5 For a digital signal, tap 0 or 1 to change the value of a signal.

For analog signals and groups, tap on 123...

to change the signal value. The soft numeric keyboard is displayed. Enter the new value and tap OK .

Note

If there is a cross connection created between two signals, changing the value of one signal automatically changes the value of the corresponding cross connected signal.

Continues on next page

276 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

7 Handling inputs and outputs, I/O

7.2 Simulating and changing signal values

Continued

For more information about changing the signal properties see the section Control

Panel,

Configuring Most Common I/O on page 114 .

Managing I/O devices

You can manage I/O devices from the I/O Devices page.

xx1700002253

Following are the actions that you can perform from I/O Devices page:

Action

Activate/Deactivate

Signals

Actions - Bit Values

Actions - Identify

Output

Activates or deactivates a selected I/O device.

Displays the signals associated with the selected I/O device.

Displays the input and output bit values of the selected device.

Displays the MAC ID of the selected device.

Actions - Configure

Note

Actions - Identify option is available only for the network type

EtherNet IP.

Allows you to configure the selected local I/O device.

Note

Actions - Configure option is available only for the network type EtherNet IP.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

277

7 Handling inputs and outputs, I/O

7.2 Simulating and changing signal values

Continued

Action

Actions - Firmware

Output

Allows you to upgrade the firmware.

Note

Actions - Firmware option is available only for the network type

EtherNet IP.

Upgrading firmware

You can upgrade the firmware of I/O device of type EtherNet IP. Use the following procedure to upgrade the firmware.

Action

Tap Main > Inputs and

Outputs .

Tap View > I/O Devices .

Description

The Input & Output window is displayed.

The I/O Devices window is displayed. It displays the available I/O devices.

Select the EtherNet IP I/O device.

Note

The Firmware upgrade option is available only for the network type EtherNet IP.

4 Tap Actions > Firmware .

The Device Firmware window is displayed with the details of the firmware.

5 Tap Upgrade .

xx1800000120

The firmware for the selected EtherNet IP I/O device is upgraded.

278 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

7 Handling inputs and outputs, I/O

7.3 Viewing signal group

7.3 Viewing signal group

Viewing signal group

This section details how to view signal groups.

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 114 .

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.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

279

7 Handling inputs and outputs, I/O

7.4.1 Safety I/O signals

7.4 Safety signals

7.4.1 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.

Signal name

ES1

ES2

SOFTESI

EN1

EN2

AUTO1

AUTO2

MAN1

MANFS1

MAN2

MANFS2

USERDOOVLD

MONPB

AS1

AS2

SOFTASI

GS1

Description Bit value condition

Emergency stop, chain

1 = Chain closed

From - To

From panel board to main computer

Emergency stop, chain

Soft Emergency stop

1 = Chain closed From panel board to main computer

1 = Soft stop enabled From panel board to main computer

1 = Enabled Enabling device1&2, chain 1

Enabling device1&2, chain 2

Op mode selector, chain 1

Op mode selector, chain 2

1 = Enabled

1 = Auto selected

From panel board to main computer

Op mode selector, chain 1

Op mode selector, chain 2

Over load, user DO

Motors-on pushbutton

Auto stop, chain 1

Auto stop, chain 2

Soft Auto stop

General stop, chain 1

1 = MAN selected

1 = Man. full speed selected

1 = MAN selected

1 = Man. full speed selected

1 = Error, 0 = OK

1 = Pushbutton pressed

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

Continues on next page

280 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

7 Handling inputs and outputs, I/O

7.4.1 Safety I/O signals

Continued

Signal name

GS2

SOFTGSI

SS1

SS2

SOFTSSI

CH1

CH2

ENABLE1

ENABLE2_1

ENABLE2_2

ENABLE2_3

ENABLE2_4

PANEL24OVLD

DRVOVLD

DRV1LIM1

DRV1LIM2

DRV1K1

DRV1K2

DRV1EXTCONT

DRV1TEST1

DRV1TEST2

SOFTESO

SOFTASO

SOFTGSO

Description

General stop, chain 2

Soft General stop

Superior stop, chain1

Bit value condition From - To

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

Superior stop, chain2

Soft Superior stop

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

All switches in run chain 1 closed

All switches in run chain 2 closed

Enable from MC (read back)

1 = Chain closed From panel board to main computer

1 = Enable, 0 = break chain 1

From panel board to main computer

Enable from AXC1

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

Enable from AXC3

Enable from AXC4

Overload, panel 24V

Overload, drive modules

Read back of chain 1 after limit switches

Read back of chain 2 after limit switches

1 = Enable, 0 = break chain 2

From panel board to main computer

1 = Enable, 0 = break chain 2

From panel board to main computer

1 = Error, 0 = OK From panel board to main computer

1 = Error, 0 = OK

1 = Chain 1 closed

1 = Chain 2 closed

From panel board to main computer

From axis computer to main computer

Read back of contactor

K1, chain 1

Read back of contactor

K2, chain 2

External contactors closed

1 = K1 closed

1 = K2 closed

From axis computer to main computer

1 = Contactors closed From axis computer to main computer

A dip in run chain 1 has been detected

Toggled

A dip in run chain 2 has been detected

Toggled

Soft Emergency stop

Soft Auto stop

Soft General stop

1 = Set soft E-stop

From axis computer to main computer

From main computer to panel board

1 = Set soft Auto stop From main computer to panel board

1 = Set soft General stop

From main computer to panel board

Continues on next page

281 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

7 Handling inputs and outputs, I/O

7.4.1 Safety I/O signals

Continued

Signal name

SOFTSSO

MOTLMP

TESTEN1

DRV1CHAIN1

DRV1CHAIN2

DRV1BRAKE

Description

Soft Superior stop

Motors-on lamp

Test of Enable1

Signal to interlocking circuit

Bit value condition

1 = Set soft Sup. Estop

1 = Lamp on

1 = Start test

1 = Close chain 1

1 = Close chain 2

Signal to brake-release coil

1 = Release brake

From - To

From main computer to panel board

From main computer to axis computer 1

282 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

8 Handling the event log

8.1 Accessing the event log

8 Handling the event log

8.1 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.

Open and close the event log

This section details how to open the event log.

Action

Tap the status bar.

The status window is displayed.

Tap Event Log .

The event log list 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.

Related information

Operating manual - RobotStudio .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

283

8 Handling the event log

8.2 Deleting log entries

8.2 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

Action

Tap the status bar, then the Event Log tab to open the event log.

On the View menu, 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

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.

284 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

8 Handling the event log

8.3 Saving log entries

8.3 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.

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 .

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

285

This page is intentionally left blank

9 Backup and restore

9.1 Back up the system

9 Backup and restore

9.1 Back up the system

When do I need this?

We recommend 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.

Back up the system

This section describes how to back up the system.

Action

Tap the ABB menu and then tap Backup and Restore .

Tap Backup Current System .

The Backup Current System window is displayed.

If a default path has been defined as detailed in the section

Setting default paths on page 100

, this is displayed.

xx0300000441

Note

• By default, a name for the Backup folder is created which can be renamed by the user later.

• While renaming, ensure that the name does not start with a space.

• If the folder name starts with a space, a warning dialog appears.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

287

9 Backup and restore

9.1 Back up the system

Continued

Action

Tap Advanced...

The Controller Settings window is displayed.

Note

Use this step to create the backup as a zip file. If this is not required navigate directly to the last step.

xx1700001302

Select the Backup to archive file checkbox.

Tap OK .

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.

288 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

9 Backup and restore

9.2 Important when performing backups!

9.2 Important when performing backups!

General

When creating 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.

A default path can be created to any location on the network where the backup should be stored, see

Setting default paths on page 100 .

When is backup possible?

A backup of a system can be performed during program execution, with a few limitations:

• 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.

• Do not create backups while performing critical or sensitive robot movements.

This may affect the accuracy and performance of the movement. To make sure that no backup is requested while in critical areas, use a system input with the action value Disable Backup .

The system input signal can be set from RAPID for the parts of the code that are critical for disturbances or remove the setting otherwise. For more information, see Technical reference manual - System parameters .

Note

Making a backup during production can interfere with the RAPID execution.

What happens during backup?

Beside the obvious, a backup being made, some other things happen during backup. For example, background tasks continue to execute.

Duplicated modules?

No save operation is performed in the backup command. This implies that two revisions of the same module 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. Restoring such a backup will restore both revisions of the module, so the status remains unchanged.

Continues on next page

289 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

9 Backup and restore

9.2 Important when performing backups!

Continued

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.

Faults during backup

If a fault occurs during the backup, for example full disk or power failure, the whole backup structure is deleted.

290 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

9 Backup and restore

9.3 Restore the system

9.3 Restore the system

When do I need this?

We recommend 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 the modules from the backup directory are loaded.

The Home directory is copied back to the new system’s HOME directory during the restart.

Restore the system

This section describes how to restore the system.

Action

On the ABB menu, tap Backup and Restore .

Tap Restore System .

The Restore System page is displayed.

xx0300000442

Note

If a default path has been defined as explained in the section

Setting default paths on page 100

, that path is displayed in the Backup folder path.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Continues on next page

291

9 Backup and restore

9.3 Restore the system

Continued

Action

To select the backup folder path or to select the TAR backup file format, tap ...

The Select Folder window is displayed.

xx1700001303

Select the backup folder or select the backup file which is in TAR format.

Tap OK .

The Restore System page is displayed again with the selected backup folder or file path details.

If you want to replace the current controller and safety settings with the selected backup controller and safety settings, click Advanced...

, select the Controller Settings and Safety Settings check box, and click OK .

xx1600001082

Continues on next page

292 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Action

Tap Restore .

The following screen is displayed.

9 Backup and restore

9.3 Restore the system

Continued xx1400002325

7 Tap Yes .

The restore is performed, and the system is restarted.

Note

If there is a mismatch between the backup and the current system, the following warning message is displayed.

xx1400002326

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

293

This page is intentionally left blank

10 Calibrating

10.1 How to check if the robot needs calibration

10 Calibrating

10.1 How to check if the robot needs calibration

Check robot calibration status

This section describes how to check the robot’s calibration status.

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

Calibrated then...

the robot must be calibrated by a qualified service technician.

You must update the revolution counters.

How to update the revolution counters is described in the product manual for the robot.

No calibration is needed.

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.

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

295

10 Calibrating

10.2 Updating revolution counters

10.2 Updating revolution counters

Overview

This section details how to perform a rough calibration of each robot axis, that is 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 product manual. Also, see the manual Operating manual - Calibration Pendulum 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.

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 .

en0400000771

Continues on next page

296 Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

10 Calibrating

10.2 Updating revolution counters

Continued

Action

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.

Note

When updating the revolution counters, the ongoing RAPID instruction or function is interrupted, and the path is cleared.

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.

CAUTION

If a revolution counter is incorrectly updated, it will cause incorrect manipulator 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 calibration manuals, depending on which calibration method to be used. The Product manual for the robot also contains more information about calibration.

Related information

Operating manual - Calibration Pendulum

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

297

This page is intentionally left blank

Index

Index

ABB menu, 41

approach points, 181

array

modify positions, 174

automatic mode

axes

B background

backup

default file path, 100

directory, 289 important, 289

menu, 65

system, 287

backward button, 39

backward execution

about, 214 limitations, 214

base coordinates

concept, 269 target criteria, 269

selecting, 138

baseline

battery shutdown

service routine, 221

buttons

controller, 51

cabinets, 36

calculation result, 183

calender time counter, 223

calibrating

CalPendulum

characters

entering, 89 international, 89

cleaning

FlexPendant, 24

close button, 41

connector, 37

controller

buttons, 51 ports, 51

single cabinet, 36

control tools, overview, 48

coordinate systems

default settings, 123 overview, 123

cursor

data instance, 61, 169

data types

default paths

displacements

E elongator points

emergency stop button, 18, 44

FlexPendant, 38

emergency stops

recovering, 22

enabling device, 23, 37–38, 44

event log

expressions

offs, 272 positions, 272

fieldbuses, 57

files

programs, 150

filtering

about, 93 data types, 93 files, 93 programs, 93

FlexPendant

cleaning, 24

connecting in operation, 250 disconnecting, 250

emergency stop button, 18

main parts, 37 overview, 37

rotating, 111

screen, 41

FlexPendant Explorer, 56

FlexPendant or T10

connector, 51

forward button, 39

Hard buttons, 39

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

299

Index

hold-to-run, 23, 244

using, 30, 209, 211

hold-to-run button, 37

I/O

I/O, inputs and outputs, 275

incremental movement

definition, 141

quickset, 84

setting size, 141

size settings, 84, 142

insertion point, change, 90

instances

data types, 169

instructions

backward execution, 214

changing motion mode, 165 commenting, 165 copying and pasting, 165 copying arguments, 165 cutting, 165

editing arguments, 163

handling of, 162

running from a specific, 212

undo, redo, 162

international characters, 89

IRC5 controller, 36 overview, 36

IsBrakeCheckActive, 234

J jogging

about, 121

additional axes, 130 axes in independent mode, 130

coordinated, 131

coordinate systems, 138

non calibrated mechanical units, 130 restrictions, 130 world zones, 130

jogging menu, 58

joystick, 37, 44

locking directions, 139

joystick directions

linear mode

about, 29, 208 limitations, 29, 208

linear motion mode, 129

LoadIdentify

300

service routine, 224

loads

identifying, 224

log off, 98 log on, 98

M main switch

controller, 51

ManLoadIdentify

service routine, 232

manual full speed mode

about, 29, 208

switching to, 262

manual mode

switching to, 261

mechanical unit

quickset, 79

selecting, 79, 132

mechanical units

activate automatically, 64

modifying positions, 264

Absolute Limit ModPos, 263

modules

most common I/O

motion mode

motion pointer, MP, 215

Motion Pointer, MP

about, 167

multitasking programs

about, 245 loading, running and stopping, 245

viewing, 246

network settings, 112

O offsets

about, 272

creating, 273

description, 272

operation time counter, 223

operator window, 41, 76

options

Calibration Pendulum, 66

duty time counter, 51

hot plug button, 51, 250

IRC5 Compact, 36

IRC5 Panel Mounted Controller, 36

Levelmeter Calibration, 66

MultiMove, 131

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

Index

safety chain LEDs, 51 service outlet, 51 service port, 51

P path

returning to, 254 path return region, 254

payloads

creating, 200

declarations, 201

deleting, 205

display definitions, 202 editing, 202

editing declarations, 204

identifying, 224

selecting, 135

ports

controller, 51

positions

about, 143 exact, 143

tuning, 54, 263–264, 268

product standards, 16

program a robot, 49

program data

editing, 171

menu, 61

program directory, 150

program execution start button, 39

programmable buttons

editing, 116

programmable keys

editing, 116

program pointer, PP, 215

Program Pointer, PP

about, 167

programs

about files, 150 creating, 150

default file path, 100

step by step execution, 214

stopping, 244

Q quickset

increments, 84

mechanical unit, 79

Quickset

coordinate systems, 82

Operating manual - IRC5 with FlexPendant

3HAC050941-001 Revision: G

tools, 81 work objects, 81

quickset menu, 41

RAPID, 148

redo

instructions, 162

reorient mode

reorient motion mode, 129

reset button

location, 38 using, 38

resolvers

about, 143

restart

menu, 74

restore

default file path, 100

menu, 65

system, 291

revolution counters

about, 143

battery shutdown, 221

setting, 296 updating, 296

RobotStudio

overview, 47

RobotStudio Oline Apps, 45

routines

changing declarations, 160 copying, 160

creating, 157

defining parameters, 158

deleting, 160

handling of, 157

running a specific, 213

running service routines, 217

run button, 39

run mode

quickset, 85 setting, 85

S safety

moving robots, 21

signals, 32 signals in manual, 32 symbols, 32

safety I/O signals, 280

safety signals

service routines

301

Index

signals

SIS, Service Information System

counters, 223 service routine, 223

SMB

battery shutdown, 221

soft keyboard, 89

speed mode

Quickset, 87 setting, 87

step

backward, 39 forward, 39

step by step execution, 214

step mode

Quickset, 86 setting, 86

stop button, 39

stylus pen

location, 38 using, 38

symbols

safety, 32

system

backup, 287

restore, 291

system parameters, 49

T targets

modifying, 263–264

moving to, 274

naming rules, 105

tuning, 54, 263–264, 268

task bar, 41

tasks

debugging, 107

loading program to, 246

normal, static, semistatic, 245 setting up, 245 starting and stopping, 245

tasks panel, 88, 107

three-position enabling device, 23, 38, 44

using, 30, 209

toggle buttons, 39

tool, overview control tools, 48

tool center point

about, 177

calculation result, 183

302

working area variations, 183

tool coordinates