IRC5 Basic Operations Revision d_5.pptx

IRC5 Basic Operations
ABB Robotics MYRO Training Centre

Regulation and Safety in ABB Malaysia
 Before entering our factory area, please ensure that you are
briefed by your ABB host on the basic safety & health rules
 All visitors and guests must be accompanied by ABB employees
while on a factory tour or testing
 Please ensure that your Visitor Pass is prominently displayed at all
times
 Safety shoes must be worn at the factory area unless you are in
the green zone
 Use of mobile phone is strictly prohibited when you are engaged in
critical tasks such as testing
 Do not stand or cross underneath the overhead crane while it is in
operation
 Do not smoke within the factory and warehouse area. Smoking is
allowed at designated smoking areas only
© ABB Robotic May 8, 2017

Regulation and Safety in ABB Malaysia
 For your safety, please do not tamper with any electrical
equipment
 Visitors who are under the influence of drugs or alcohol are
advised against entering the company’s premises
 Do not enter a “live” installation testing area without prior
authorization
 Please ensure that you have been briefed on ABB’s emergency
and evacuation plan
 Please exercise caution at blind corners
 Always observe and follow the traffic signs
 Please do not operate any equipment without the authorization
ABB personnel
 Report all incidents, near misses, unsafe acts and unsafe
condition to your ABB host

Emergency procedure
You are here

Emergency procedure
 Upon hearing the first alarm - stop work or discussion
 Once you hear the second emergency alarm – follow your
ABB host to evacuate the building
 Use the nearest exit
 Do not run or panic
 Use the staircase. Do not use the lift during an emergency
 Proceed to the emergency assembly area
 At the assembly area, please follow instructions of ABB
personnel in-charge
 All clear signal – please wait for the all clear signal before
re-entering the building
Please dial 4816
for all
emergencies

INTRODUCTION

Course Content
Section Description
1 Introduction
2 Safety
3 System Description
4 Getting Start
5 Jogging & Coordinate System
6 IO Signal
7 Handling Programming
9 Backup and Restore
10 Event Massage
11 Restarts
12 Calibration

BASIC OPERATION
Course time : 0900 - 1630
 Breaks : Tea/Coffee : 1030 – 1050 Lunch : 1230 – 1330 Tea/Coffee:1500 - 1520
Day 1
Safety
System Description
General
Controller
Manipulator
Operator’s Panel
Teach Pendant
Getting Start
Starting the System
Flex pendant Handling
Robot Coordinate System
Tool Coordinate System
Work Object Coordinate System
I/O Signal
Day 2
Handling Program
Program Data
TCP
Work object
Load and Run Program
- Program editing
- Modify Position
- Routine & data viewing and editing
Programming
- I/O Instruction
- Movement Instruction
- Circular movement
Day 3
Save program and module
Backup
Event Message
Restart
Calibration

Course Objectives
 Practice safety as it pertains to the robot system.
 Identify and use the Flex Pendant.
 Run the robot system in manual mode and automatic mode.
 Interpret and respond to event messages.
 Load, save, and edit basic programs using the Flex Pendant.
 Modifying movement instructions in a basic program.
 Understand the use of input and output instructions in a basic
program.
 Manually manipulate I/O to release and activate tooling.
 Create and Define a tool center point
Upon completion of this course the student will be able to
successfully:

Course Objectives
 Use movement instructions in a basic program..
 Create routines, and use routine instructions in a basic
program..
 Understand and update Revolution Counters.
Upon completion of this course the student will be able to
successfully:

SAFETY

Robot Safety during training course
Keep fingers clear of gripper jaws when loading parts
Stand clear of robot benches when running programs
Test all program modifications in a manual mode first
Full speed modes are permitted with instructors assistance
Be cautious when releasing brakes
When inside the robot cell, make sure you have control of Pendant

Safety Solutions – an Overview
Pinch Points
Lock Outs
Emergency stop
Operating mode
Auto
Manual < 250 mm/s
Manual 100% (Option)
Enabling device
(Dead mans grip)
Hold-to-run
Safeguard stop
(Auto and Manual)
Limiting the workspace
Enabling device
Hold-to-run buttons
(for left or right hand)

Pinch Point
Evaluate the machine and its movement to identify and avoid pinch points
 Pinch points are any
areas where you can
get caught between
the moving parts of a
robot and stationary
object.
 Physical guards
create a barrier to
prevent you from
getting trapped or
injured in pinch point

LOCK OUT/TAG OUT
Proper Lock Out /Tag Out practices and procedures safeguard yourself and
other from release hazardous energy. To lock out turn the key switch to
Manual Mode, then turn the rotary disconnect to the Off position. Open
the locking mechanism on the disconnect & place your lock or a multiple
“gang lock” device on the disconnect.

LOCK OUT /TAG OUT (LOTO)
OBJECTIVE
 Preventing the unexpected start up or release of stored energy from equipment
during maintenance and repairs to protect employees from injury
 To prevent equipment from unexpectedly being set in motion and endangering
workers.
 Potential hazardous energy sources must be identified ,isolated and locked
and tagged out before starting a service/ maintenance tasks

Emergency Stop
Pressing an Emergency Stop button will
stop the robot motion immediately.
Built-in emergency stop push buttons are
found both on the FlexPendant and Control
module.
Additional emergency stops can be
connected to the robot system’s safety
chain.
Recover by rotating pushbutton to reset and
pressing the Motors On button.

Operating Mode
 Automatic mode
 Production mode (no speed limit)
 Manual mode
 < 250 mm/s – max velocity 250 mm/s
 100 % – Option, robot can be jogged/tested
with no speed limit.

Manual Full Speed (Optional)
Press and Hold down the play key, to run the program
Press and Hold down the FWD or BWD key to step
Releasing the pressed key to stops execution
1
2

Enabling Device (Dead Mans Grip)
 The enabling device is a press switch with three positions
 The switch must be in the middle position in order to
activate the motors
 All robot movement will immediately stop if the switch is
released or pressed to the bottom
Enabling device

Safeguard Stops
 Your robot system can be equipped with a vast range of safeguards such as
door interlocks, safety light curtains, laser scanners and pressure mats etc.
 A safeguard prevents hazardous situations by stopping the manipulator in a
controlled manner when a mechanism such as a light curtain is activated
 The controller has three separate safeguarding mechanisms,
 General stop (GS) Always active regardless of operating mode
 Automatic stop (AS) Only active in auto mode
 Superior stop (SS). Always active regardless of operating mode

Limiting the Workspace
 To avoid the risk of getting caught between
the robot and the perimeter safety
equipment, e.g. a fence, the robot’s
workspace can be limited:
 All axis can be software limited
 On some robots Axis 1–3 can be limited
by adjustable mechanical stops and
controlled by limit switches

Working range of robot axis
 All Axis are software controlled to limit their rotational range
 The software stop should prevent collision at the end of axis
rotational travel
 Axis 1–3 can on larger robots, can be fitted with adjustable
mechanical stops
 Training robots axis are set to the default maximum range

Electrical Safety
A danger of high voltage is associated with, for example,
the following parts:
 Be aware of stored electrical energy (DC link, Ultra capacitor bank unit) in the
controller.
 Units such as I/O modules, can be supplied with power from an external
source.
 The mains supply/mains switch
 The transformers
 The power unit
 The control power supply (230 VAC)
 The drive system power supply (230 VAC)
 The service outlets (115/230 VAC)
 The customer power supply (230 VAC)
 The power supply for the motors (up to 800 VDC).
 The external voltage connected to the controller remains live even when the
robot is disconnected from the mains.

Brakes Release
 The brakes on the robot motors can be manually released
 Make sure the weight of the robot axis and tooling are supported
 Brakes are reapplied when button is released
IRC5C controller
brake release button

Safety Regarding Grip Device
 All grip devices must be designed so the work piece will be held even on
power failure and other disturbances in the robot system
 There should be possibilities to loosen the work piece manually
 Familiarize yourself with operational buttons assigned to the gripper function

Personal Safety
Principles should be followed in order to operate the
robot system safely:
 Always operate the robot system in manual mode if personnel are inside
safeguarded space.
 Always bring the Flex Pendant along when you enter safeguarded space so
that robot control is in your hands.
 Watch out for rotating or moving tools such as milling cutters and saws.
Make sure those are stopped before you approach the robot.
 Watch out for hot surfaces both on work pieces as well as on the robot
system. The robot's motors can become fairly hot if run for a long time.
 Watch out for grippers and objects gripped. If the gripper is opened the work
piece could fall and cause injuries or damage equipment. The gripper can be
very powerful and can also cause injuries if not operated in a safe manner.
 Watch out for hydraulic and pneumatic systems and live electric parts. Even
with power off residual energy in such circuits can be very dangerous.

Accident Risks
 Fault tracing
 Repair
 Change of program
 Test run

Accident Risks
Fault tracing
 Fault tracing and repair procedure
go hand in hand .you are at your
vulnerable when you’re fixing a
robot.
 Never rush through the steps and try
to work around the safety
procedures .

Accident Risks
Change Program
 A program change may mean what
was safe space yesterday isn’t a
safe space today
 Be sure you are following procedure
and clear communicating
information about any program
changes

Accident Risks
Change Program
 Anytime you change a program,
make sure you perform a test run
 Check to make sure the robot
moves the way you intended without
any programming mistakes.
 Accidentally forgetting a clearance
position in the robot’s program may
cause someone serious harm and
injury.

SYSTEM DESCRIPTION

Robot System
Manipulator IRB6700
Controller IRC5
Programming Unit
FlexPendant

Controller IRC5 - Single cabinet
Main Switch
E-Stop
Motor on Button
Selector Key Switch
Ethernet Port
Hour Meter

Controller IRC5 - Compact
Main Switch Emergency Stop Button
Motors on
Selector Key Switch
Brake Release Button

IRC5 Compact (Controller
Overview)
Main Power
Connector
Manipulator Connectors
Operator´s Panel Digital I/O
Safety
Presently not
used
FlexPendant
connector
Brake
Release
(IRB120 only)
Main Computer front with
CF memory, ports and PCI slots
DeviceNetTM
Lean
For external I/O units
Customer 24 V
Presently not used
Main Switch

IRC5 Single Cabinet (Controller Overview)
Main Computer
Unit
 Field bus
adapter:
 Ethernet
I/PTM
 PROFIBUS
DP
 PROFINET
IO
Compact Flash
mass memory
I/O units or PLC
Main Drive
Unit
Additional Drive
Unit
Front connectors
behind cover
UltraCap
Main Computer
Panel
Unit
Power Supply
Axis Computer
Hot Plug (option)

Example of Industrial Robot– IRB 6700
Large robot- 6 Axis

Small Robot -6 Axis

4 Axis Robot

Parallel Robot- 4 Axis

Product Range

The ABB robot family
Reach up to 3.5m
Payload up to 630kg

Small robot family
Payload 3kg to 10kg
IRB 120 & 120T
3kg 0.58m 7kg 0.7m
IRB 1200
5kg 0.9m
IRB 1200 IRB 140 & 140T
6kg 0.81m
IRB 1600
6kg &10kg 1.2m
IRB 1600
6kg &10kg 1.45m
IRB 1600ID
4kg 1.5m
IRB 1520ID
4kg 1.5m

Medium robot family
Payload 8kg to 60kg
IRB 2600ID IRB 2600ID
8kg 2.0m 15kg 1.85m
IRB 2400 IRB 2600 IRB 2600
12kg 1.85m
12kg & 20kg 1.65m
12kg & 20kg 1.55m

Medium robot family
Payload 8kg to 60kg
IRB 4400
IRB 4600 IRB 4600
IRB 4600
20kg 2.5m
60kg 1.96m
45kg & 60kg 2.05m
40kg 2.55m

Large robot family
Payload 90kg to 650kg
IRB 6640
185kg 2.8m
IRB 6640
205kg 2.75m
IRB 6640
235kg 2.55m
IRB 6640
130kg 3.2m
IRB 6640ID
200kg 2.55m
180kg 2.55m
IRB 6640
IRB 6640ID
170kg 2.75m

Large robot family
IRB 6660 Pre-machining
IRB 6620
IRB 6660 Press Tending
IRB 6650S
IRB 6620LX
205kg 1.9m 130kg 3.1m
150kg 2.2m 90kg & 200kg 3.0m & 3.9m
150kg 1.9m

The IRB 6700 Large Robot Family
IRB 6700
175kg 3.05m
300kg 2.7m
IRB 6700
240kg 3.00m
IRB 6700
IRB 6700
150kg 3.2m
IRB 6700
155kg 2.8m 200kg 2.6m
IRB 6700
IRB 6700
205kg 2.8m
IRB 6700
235kg 2.65m

Large robot family
400kg 2.55m
340kg 2.8m
500kg* 2.55m
IRB 7600
325kg 3.1m
150kg 3.5m
IRB 7600
* 630kg capacity
with wrist down
IRB 7600 IRB 7600
IRB 7600

High speed pickers Palletizers
Top loader and packer
Dedicated 4 axis robot family
Overview - picking, packing, palletizing
Serving fully
integrated
packing lines

Dedicated 4 axis FlexPicker family
High speed pickers from 1kg to 8kg
 Stainless steel
option
 Protection to
IP55/67/IP69K
 Clean Room ISO
Class 5-7
 Wash Down
3kg 1,130mm
1kg 800mm 1kg 1,130mm
1kg 1,600mm 8kg 1,130mm
6kg 1,130mm

Dedicated 4 axis robot family
Top Loaders & Palletizers
IRB 260
IRB 660 IRB 660
IRB 460
IRB 760
+ Grippers
30kg 1.5m 110kg 2.4m
450kg 3.18m
180kg 3.15m 250kg 3.15m

Compact version
Panel mount version
Robot control family
Overview
 Multi-robot control, up to 36 axis, with MultiMove
 Programmable user interface with intuitive joystick control via
FlexPendant
 World leading motion control with TrueMove and QuickMove
 “Next generation safety” with SafeMove
 Powerful connectivity through network interfaces
 Remote Service option
Modular version

Paint robot family
With dedicated controller
IRB 52 IRB 580
IRB 5400 IRB 5400 with Rail IRC5P
All ABB paint
robots, paint
controllers
and paint
programming
units are
explosion
protected.
See data sheets
for more
information
IRB 5500
13kg 3.0m & 5.8m
7kg 1.22m & 1.45m 10kg 2.2m & 2.6m
25kg 3.1m Paint Controller
25kg up to 20m

Robot process and application equipment
Fully integrated with your robot
Dress Packs
Painting Track Motions
Process Cabinets Arc Welding Spot Welding

RTT tracks for small robots.
IRBT 4004, 6004, 7004 tracks for large robots.
IRT tracks for other objects.

Motors
Positioners Grippers
Press tending tools Gearboxes Additional axis

L type positioner (5 sizes)
C type positioner (2 sizes)
R type positioner (3 sizes)
K type positioner (3 sizes)
A type positioner
(3 sizes)
B type positioner (3 sizes)
D type positioner
(2 sizes)

FlexLifter (3 models)
FlexPLP (3 models)

Force control
Vision Dispensing
Dusting Press synchronization Door openers

Getting Start

Starting the System
 Before switch ON the system, make sure that there
is no one inside the safeguarded space around the
robot.
 Switch ON the mains switch. The robot is then will
automatically checked.
Mains Switch
OFF ON

Starting the System
Switch ON the Main Switch at the controller to
power ON the system.
MAIN
SWITCH

Starting the System (Welcome Screen)
 After the system has been checked and no errors are located, the
welcome message appears on the display.
Welcome Screen

FlexPendant Overview
Status bar
User defined keys
Windows
button
Program execution keys
E-Stop
3D
Joystick
Enabling
device
USB port
Quickset menu
Jogging
keys

IRC5 – FlexPendant
Main Menu

QuickSet menu overview
With the QuickSet menu you can access some often used settings
Mechanical unit jogging mode (Not allowed in Auto)
Incremental jogging (Not allowed in Auto)
Running Mode Cycle or Continuous
Step Mode (In, Out, Over, Next move)
Override Speed (+/- 1%, 5%, 25%, 50%, 100%)
Tasks (task activation / deactivation)

Mechanical Unit: A feature that allows the handler to choose between the robot
and the motion modes for the robot and external axis, this is also where you can
choose the coordinates and active tool, and active work object.
When multiple Robots are on a
system, the Blue Box indicates the
current selection.
Quickset Menu Description

Show/Hide Details: By Tapping on the Show Details button, your current selections
can be viewed. The button will change back to Hide Details if hit again allowing you
to minimize that screen.
The selected Coordinate system,
and Motion Mode setting is
displayed when Show Details is
pressed. Tap on one of the other
selections to change that property.

Increment: Use incremental movement to jog the robot in small steps, which
enables very precise positioning.
 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 move continuously
when the joystick is deflected.

Run Mode: By setting run mode you define if the program execution should run
once and then stop, or run continuously
Single Cycle: Runs one cycle then
stops execution.
Continuous: Runs continuously..

Step Mode: Selecting the different Step Mode features allows you to define how the
Step-by-Step program execution will function.
Step Into: Steps into called routines
and executes them step-by-step.
Step Out: Executes the remains of
the current routine and then stops at
the next instruction in the routine
from which the current routine was
called.
Step Over: Called routines are
executed in one single step.
Next Move: Steps to the next move
instruction. Stops before and after
movement instructions, for example
to modify positions.

Speed: The Speed settings apply to the current Operating Mode. But, if you
decrease the speed in Automatic Mode, the setting also applies to Manual mode if
you change back to that mode. The current running Speed, in relation to Max, is
displayed above the buttons.
-1% & +1%: Decrease & Increase
running speed in steps of 1%.
-5% & +5%: Decrease & Increase
running speed in steps of 5%.
25%: Run at quarter speed (25%).
50%: Run at half speed (50%).
100%: Run at full speed (100%).

Tasks: If you have the option Multitasking installed there can be more than one Task.
Otherwise there is only one Task. By default, only normal Tasks are possible to
activate/deactivate in the Quickset menu. Using the Control Panel you can however
change the settings so all Tasks are possible to activate & deactivate.
Activated tasks are started and stopped with the Start and Stop buttons on the
FlexPendant.
The green checkmark indicates
which Task is selected.

Exercise

Exercise
1. Go to your assigned robots and practice jogging the robot
using the Quick Set button and the joystick.
2. What happens when you press the top center box on the Flex
Pendant?
3. Look at the Event Log. What was the last event that occurred?
4. Challenge: Find and Change the FlexPendant display
Brightness and contrast.
5. Challenge: Find and Change the FlexPendant for either Right
or Left handed users.
6. Practice pressing buttons on the FlexPendant. If you have any
questions ask the instructor.

Jogging and Coordinate
System

Jogging the robot

Jogging the robot
 Basic Setting for jogging
 Select Mechanical Unit
 Select Motion Mode
 Select Coordinate System
 Select Tool
 Select Work Object

6 Axis Robot
Axis 2
Axis 3
Axis 4
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
+

4 Axis Robot (FlexPalletiser)
• A = Axis 1
• B = Axis 2
• C = Axis 3
• D = Axis 6
A
B
C
D
+

3 / 4 Axis Robot (FlexPicker)
1
3
2
Y
X
4
Z Base coordinate system

Jogging 6 axis robot
1
2

Jogging along Coordinate axis
1
2

Jogging Motion Keys
 Mechanical unit activation switch
 Linear / Reorient
 Group 1 / Group 2 Axis
 Activate / deactivate incremental jogging

Jogging External Axis Track

Jogging External Axis Positioner

Incremental Jogging
 Greater jogging control
 Small = 0.05mm
 Medium = 1mm
 Large 5mm
 User from 0 to 5mm
 Show values to edit User
2
1
3

Jogging collisions
 Disabling Jog supervision allows robot to be jogged after collision
 ‘Collision Detection’ Software option (613-1), required
 Path supervision is not effected only jog supervision
 Try before releasing brakes
Disabled

Jogging Override Speed
 Used when the default 100% value feels to sensitive
 Value can be set to a percentage of the default jog speed
 Reduce percentage will be slower and less sensitive
 Jog speed is still proportional to joystick deflection

The Jogging Window

Jogging the Robot
-Y +Y
-X
-Z
+Z
+X
+X
+Y
+Z
-Y +Y
-X
-Z
+Z
+X
X
Z
Y
-2
-1 +1
+2
-3
+3
+1
-1
+2
-2
+3
-3
-4 +4
-5
+5
-6
+6
-4
+4
+5
-5 +6
-6

Z
X
Y
WorkObject
Coordinate
Coordinate System
Base
Coordinate
Z
Y
X
Tool
Coordinate
World)
Z
Y
X
Z
Y
X

Right Hand Rule
The Right Hand Rule applies to all coordinate
systems

Exercise
Jogging the Robot Arm


Position the robot joints

Major Axis

Minor Axis

Increments where required

Position the tool using Linear relative to:

World / Base coordinates

Tool coordinates

Work object coordinates

Increments where required

Position the tool using Orientation relative to:

Tool / Base and Work object coordinates

Practice Tool Alignment
Jogging demonstration

Handling inputs and outputs,
I/O

IRC5 – Flex Pendant (I/O Output)
Inputs and Outputs Window
I/O signal properties is used to view the input and output signals and their
names, values and type
Signals are configured with system parameters

I/O Unit status is recognized by the system ( Board )
Individual input/output signal characteristics can retrieval and manipulate.
Manual operation is only allowable force for the individual signals.
The output signal operation Off (value 0) and On (value 1)
Input Signal Operation: First, press simulation, it can be operated via the same method.

Most Common I/O
Signal type and relationship of critical signals it can be grouped into a separate group.

Viewing signal
Tap Menu
Tap Inputs and Outputs
Tap View.
Select signal type

Define and Using a Tool

Tool Centre Points (TCP)
+X
+Y
+Z
Wrist Coordinate system
Tool Coordinate system

Tool Centre Point theory
 The position & movement of the robot is always relative to the active TCP.
 TCP’s are defined as being somewhere at the end of the tool.
 Many TCP’s may be defined, but only one active at any one time.
 Can be programmed manually but only if accurate TCP values are known.
 Normally the robot is used to define its TCP.
 If tool is damaged or replaced, don’t modify program positions, just redefine
the tool.

 Default Orientation (same direction as Wrist coordinate system)
 TCP & Z Just Z direction defined (X stays in same plane as wrist)
 TCP & Z, X both Z and X defined
 From 3 to 9 approach points
Tool Centre Point Definition Methods

Example of TCP with default orient
 No rotational difference from the wrist coordinate system

Example of TCP with Z direction defined
 The TCP’s X&Z are in the same plane as the wrist

Example of TCP with Z&X directions defined
 The TCP’s X&Z directions are rotated differently to the wrist

1
2
3
4
1
2
3
Plan view
4
TCP Definition – Default Orient

1
3
6
5
4
Jog robot so the tool’s intended Z and X
directions, visually align to the base
coordinate’s Z and X axis.
Jog along Base coordinate Z Axis to
define tools Z direction
Jog along Base coordinate X Axis to
define tools X direction
Z Elongator point
2
Tool orientations are defined by the direction the tool is
positioned away from the datum point.
X Elongator point
TCP Definition – Z & X

Tool Centre Point Definition Method
 Menu
 Program data
 Select tooldata
 Show data
 New…
 Name tool
 Initial value or OK and then select tool in list and Edit Value
 Mass:= type in kg and Centre of Gravity
 Press OK
 Press Edit
 Select Define
 Select Method and number of Points
 Select Point 1, jog robot to calibration position and press Modify Position
 Repeat for remaining points
 Press OK
 You will need to activate your TCP in the jog window

Exercise
Create a Tool Centre Point
Exercise 2

Handling Program

Programming Introduction
 Load an existing program
 Introduction to basic move instructions and data
 Programming move instructions
 Modifying Instructions and data
 Save a program
 Rename a program
 Delete a program

Program Modules.mod
Program Data
Main
Routine
Routines
<?xml version="1.0" encoding="ISO-8859-1" ?>
<Program>
<Module>MainModule.mod</Module>
<Module>ModuleA.mod</Module>
<Module>ModuleB.mod</Module>
</Program>
Program Data
Routines
Program Data
Routines
System Modules.sys
Program Task Structure

Rapid Program
A program is the list of command that tells robot what to do
Programming language: RAPID (Robotics Application Programming Interactive Dialogue)
- 4th generation language. RobotWare is written in C language, 3rd generation language.
Program = data + Instruction/commands (Instruction/commands are handled in units of
routines)
A program operates in conjunction with a program module and a system module, and
there is only one program in the program memory. (Extension: *. pgf)

Internal Structure of Module

Modules
 A module contains routines and data’s.
 The module that contains the main routine is the MainModule
 System modules are always present in memory and can be used to save your
default data
 Filename extensions are
 XXXXX.mod Program Module
 XXXXX.sys System Module
 XXXXX.pgf Program File

Routines
 Repetitive instruction sequences, that occur frequently in the program, should
form their own routines.
 Routines separate the program into smaller more easily understood parts,
these can then be called anywhere in the program using the ProcCall
instruction.
 A Max of 16 characters are allowed for naming routines, meaningful names
will make the program easier to follow and operate.
 Routines can be tested by moving the Program Pointer to a routine. (Debug)
 Routines are called within the program using the instruction ‘Procall’

Routines and program flow example
 The Main Procedure controls the flow of the entire program
 Sub Procedure routines do the jobs
 The ProCall Instruction is used to program the call of the routines

Instructions
An instruction defines a specific task that is to be carried out when instruction
is executed, for example
 Moving the robot
 Setting an output
 Changing data
 Jumping within the program
Instructions comprise an instruction name and a number of arguments.
The name specifies the principal task of the instruction and the arguments
specify the characteristics
Example:
MoveL p1,v500,fine,tool1
Moves the TCP linearly to the position p1. The arguments, v500, fine and
tool1, specify the current speed, position accuracy and tool.

Introduction to Joint & Linear Motion
Move L
Move J

 MoveJ is used to move the robot quickly from point to point
 The movement will not be in a straight line.
Positional Movements Instructions (Common Picklist)
Robtarget Speed Zone Tool

Positional Movements Instructions (Common Picklist)
 MoveL moves the TCP in a Linear direction or straight line.
Robtarget Speed Zone Tool

Zones
z
MoveL p40, v1000, z50, tool0;
MoveL p30, v400, z20, tool0;
Zone data describes how close to the destination position
the axes must be before the next instruction can be executed
Zone size

Moving Circular
MoveC - moves the TCP in a Circular direction
using the mid & end point of a semicircle
MoveL *, v100, fine, tPen WObj:=wobj1;
MoveC *, *, v100, z10, tPen WObj:=wobj1;
mid
end

Programming MoveC
p1
p2
p3
p4
ModPos End target here
Pick MoveC here
MoveL p1, v100, fine, tPen WObj:=wobj1;
MoveC p2, p3, v100, z1, tPen WObj:=wobj1;
MoveC p4, p1, v100, fine, tPen WObj:=wobj1;

Input Instruction
Input processing instructions are to wait until you are satisfied the specified conditions.
Conditions can be such signal conditions, the time, the logical operation.
WaitDI di05_AutoReady, 1;
WaitTime 0.5;
WaitUntil di06_Ready = 1;
WaitUntil di05=1 AND di07=0;
WaitUntil di02=1 OR di03=1...;
Signal state
Signal Name

Set do03_Clamp;
Reset do03_Clamp;
Signal
t
1
0
Signal
t
1
0
0.2s 1.0s
PulseDO PLength:= 0.2, do12;
PulseDO PLength:= 1.0, do12;
SetDO SDelay:=1.5, do04, 1;
SetDO do04, low;
Output Instruction
Signal
t
1
0
1.5s

I/O Timing
p40
p30 p20
DT
DT is a time dependant on processor load.
p10

P40
P30
I/O Timing
P20
p10

Creating New programs
 New Programs can be created in the Program Editor
 Program names can not start with a number
 If a program allready exists, it will be overwritten
 New programs are temporaraly called ’NewProgramName’
 A ‘main’ routine is created within a ‘MainModule’

Loading Programs
 Loading whole programs will overwrite existing
programs
 Each task will have its own program

Loading Modules
 Loading Program and System modules from the Program Editor

Creating a new Module
 ABB menu
 Tap Program Editor.
 Tap Modules.
 Tap File, then tap New Module.
 Tap ABC... and use the soft keyboard to enter the new module's name.
 Then tap OK
 Select which type of module to be created:
• Program
• System
 Then tap OK.

Creating a new Module

 How to create and program routines.
 Must be in the Program Editor.
 Tap Routines : File
 New Routine : Tap “ABC…”
to change the name.
 Tap OK.
 Select the routine.
 Tap Show routine.
Creating Routines

To add instructions to your program:
 Tap Add Instruction
 Jog robot into position
 Tap MoveJ or MoveL
 Jog robot to next position
 Repeat
Inserting Move Instructions

Exercise
Programming movements
Exercise 1

 Select the instruction or target to be changed (Step is recommended)
 Jog robot to the desired position
 Press Modify Position
Modify Position

Changing a Program
Select item to
change by double
Tapping.
Then choose new
value and press
OK.

Program Edit

Debug
Program
Pointer (PP)

Exercise
Programming with Routines
Exercise 5

 Create a new routine called PickPen
 Activate your TCP
 Program the robot to pick up the pen
 Test this routine (debug ‘PP to routine’)
 Copy this routine and edit the output instruction to put the pen down
 Test the duplicated routine (debug ‘PP to routine’)
 Call these routines within your main routine (ProCall instruction)
 Test your Main Routine (debug ‘PP to main’)
 Save your program as ‘Exercise_3’
Routines Exercise

Start / Finish
Direction
Start / Finish Start / Finish
Path Following Exercise
Path Following Exercise

Running Program

Running Programs in Manual Mode
Procedure
Step Action Info/Illustration
1 Switch the robot to Manual Mode.
2
DANGER!
Before running the robot, please observe the safety
information in section DANGER – moving
manipulators are potentially lethal!

Running Programs in Manual Mode
Procedure
3 Press Enable Device.
4 Press the Start button on the Flex Pendant.
Run / Start Program
Execute Backward/Forward
Stop program

Starting Execution
Procedure
1 To run a selected execution use the “Run" button
on the Flex Pendant's hardware button key set.
Run / Start Program
Execute Backward/Forward
Stop program

Stepping Instruction by Instruction
In Manual Mode, the program may be executed step-by-step forwards
or backwards
 There are number of dedicated hardware buttons on the FlexPendant
Programmable button 1. How to define it's function is in the
IRC5 Pocket Guide.
IRC5 Pocket Guide.
IRC5 Pocket Guide.
IRC5 Pocket Guide.
RUN button. Starts program execution.
STEP BACKWARDS button. Steps the program one
instruction backwards.
STEP FORWARDS button. Steps the program one
instruction forwards.
STOP button. Stops the program execution.

Stepping Instruction by Instruction (2)
Select stepping mode
1 Selection of step mode.
Stepping forward
1 Press the FWD button on the FlexPendant as
shown in the illustration on earlier page.
Stepping backward
1 Press the BWD button on the FlexPendant as
shown in the illustration on earlier page.

Stopping Execution
Procedure
1 During operation with hold-to-run control:
Release the hold-to-run button.
2 During operation without hold-to-run control:
Press the STOP button on the FlexPendant unit.
3 When running in step-by-step mode, the robot will
stop after executing each instruction.
Execute next instruction by
pressing FWD or BWD again.

Saving Program

Saving program in IRC5
 A folder with the same name as the program is created
 This folder contains the MainModule, Sub modules and the program file
 The program file (.pgf),is an extensible mark-up language, ‘XML’, file that lists all
program modules in the task
 System Modules are NOT saved

Saving Program
Robot Task
MainModule.mod System Modules.sys
Program File.pgf
Program Data
Routines
Program Data
Main
Routine
Routines

Saving Individual Modules
 Individual, Program or System modules can be saved
 Select in ‘Program Editor’ and ‘Save Module As…’ from File menu

Program Data
Routines
Saving Module
Robot Task
System Modules.sys
Program File.pgf
Program Data
Routines
Program Data
Main
Routine
Routines
MainModule.mod Module1.mod

Exercise
1. Go to your assigned robots and create a simple program as described in
this section. Then test your program. Each student should make their own
program. (Do not use I/O until all participants have created and tested their
programs.)
2. What happens when you press the E-Stop button while the robot is
running? Can you restart the robot from where it stopped?
3. Save the program to the Flash Drive.
4. Practice pressing buttons on the FlexPendant. If you have any questions
ask the instructor.

Backup and Restore

Backup
Having a valid backup is necessary for fast recovery:
If the system behaves differently. (Other than normal)
After software upgrades or reinstallation.
What does a backup contain?
All of the files/folders stored under Home directory in your system on your
flash drive.
The system parameters (e.g naming of I/O signals)
All current programs, modules, and tasks currently in memory.
A backup contains the info that allows your system to go back to behave as it
did when the backup was taken.

Backup Structure
TASKS
Copy of
Systems
‘home’
folder

Backup and Restore – Backup the System
ABB recommends performing a backup:
Before installing new Robot Ware
Before making any major changes to instructions and/or parameters
to facilitate the previous setting
After making any changes to instructions and/or parameters and
testing the new settings to retain the new settings
Remarks:
Always
Give your backup a good name. Push to go to the key board to
type the name of the backup.
Pay attention to the Backup Path, this is the location where the
backup will be stored. Push the … to change the location.
You should create a Backup folder to store the file in.

Backup
 Perform Backup

Exercise 6
Backup and Restore System
Backup and Restore Exercise

Even Messages

Event Messages are divided into.
Information
Example: Hold to run must be pressed.
Information is stored in the log.
Warning
Example : Manual movement full speed is selected.
The operator is informed about a potential risk.
Error
Example : Motor On when Emergency Stop is active.
The system cannot operate before a measure is carried
out.
Introduction

Information
Example: Information at program start:

Warning
Example: When the computer detects a situation that can cause a
problem or is a safety risk

Error Message
Example: When the computer detects a problem or possible problem, it
generates an error message with description and action.
Unacknowledged message is displayed in red on the status bar
Unacknowledged
message displayed

Event Message Content
An Event Message consists of
 Description
 Consequences (optional)
 Probable causes (optional)
 Action (optional)
Tap arrow to scroll down
in message!

Reading Event Logs on the FlexPendant
Via ABB - Main menu
Tap status bar – Short cut
Tap on Status Bar to see
Event log.
Or Tap ABB then Event
Log to see Event log.

Event Log
Code Title Time stamp
Symbol

Scroll the list with the yellow arrows
Tap on a specific message to get more information
Event Log

Event Log
Logs are stored under different topics
Tap view and select the topic of interest
Topic common consist of a mixture of the last created logs
Log Messages
Common 150
All others 20

Event Categories
Category Error number Area__________________
Operational 10xxx Operational Status
System 20xxx Panel unit
Hardware 30xxx Board Failure
Program 40xxx Programming
Motion 50xxx Movement problem
Operation 60xxx Flex Pendant Handling
I/O communication 70xxx I/O board communication errors
ArcWeld 11xxxx Process
SpotWeld 12xxxx Process
Paint 13xxxx Process
Refer to the error number when support is
needed!

Restarts

Restart
 In ABB/Main menu select restart

Restart Advanced Menu
 If another restart than Warm Start is required
Tap Advanced

Restart (Warm Start)
 When: New hardware, SYSFAIL or change in configuration
 Result: Current system is restarted. Program pointer are restored
Reset System (I- start)
 When: Add RobWare for a new process
 All saved, Restart with default parameters.
 Modules & program not loaded
Reset Rapid (P-Start)
 When: E.g. Changing data in parallel tasks
 All data saved on image file for loading purpose
 RAPID programs not reloaded
Summary of Restart Alternatives

Summary of Restart Alternatives
Start Boot Application (E-start)
 When: Change to an existing system: E.g: Glue to Arcweld
 All data are saved on an image file, for loading purpose only
C-Start (Cold start) Removes all user inputs and the robot software
 When: E.g: A new BaseWare for a system shall be loaded
 All data is erased. A boot is necessary if no other system exists in the controller

Special Restart Alternatives
Shutdown
When: The UPS system is not working
 An image file is carried out as a normal Power Off
 To start: Turn Power Off & On to restart the system
Revert to last Auto Saved (B-Start)
When: E.g. Recommend action from an error message
 Returns the system to the state after the most recent shutdown by either Power
Off or Shutdown
 In this case no saving is carried out as for Warm Start
Note! These alternatives are intended for special use only!

Calibration

 Fine Calibrate or Rev.Count update?
 Rev.Count update can easily be made with no special
tools.
 Fine calibration needs special tools.
Calibration – IRC5

 Rev.Counter
 Tells how many turns the motor has rotated in the
gearbox.
 If value is lost the robot cannot run any programs.
 A message notifies that the Rev.Counters need to be
updated.
(e.g. If battery in SMB is drained)
Rev. Counters
If Event message The
system informs about
difference:
Update so that the robot
and the controller have
the same calibration
values
©
ABB
Inc.-184

Updating Rev. Counters
1. Use the Joy stick and
Move the Robot to
the Calibration
Position and align
the witness marks.

Synchronization Marks
IRB120
A: Axis1, B: Axis2, C: Axis3, D: Axis4, E: Axis5, F: Axis6

IRB2400, 4400

IRB2600, 4600

IRB6640

IRB6660
A: Axis1, C: Axis2, D: Axis3
E: Axis4, F: Axis5, G: Axis6
A
D

IRB660,760
A: Axis1, C: Axis2, D: Axis3, E: Axis6

IRB360
A: Axis4, B: Axis1-3

Updating Rev. Counter Procedure
1. Jog the robot to the witness marks / Calibration position.
2. Tap ABB : Calibration
3. Select the robot to be calibrated.
4. Tap Update Revolution Counter
5. Tap YES to confirm this is what you want to do.
6. If needed select the axes to be updated.
7. Tap Update and Update again.

 MoveAbsJ
 Create a new routine (GotoCalib)
 Insert MoveAbsJ instruction
 Choose star position, Debug / View Value, put all 6 axis
to zero
Checking Robot Calibration

 Fine Calibration
 Tells the current angle of motor shaft when robot is in
sync position
 Is tuned in by ABB or on site with special equipment
 Only needs to be retuned if a motor / gearbox is
replaced
Fine Calibration
Requires special tools!
Cannot be made correctly
by eye Measurement.

 Type in the fine calibration values manually
 Use moc.cfg values from Backup, Silver label in back of
manipulator with 6 values, or original Motor Calibration
values on floppy shipped with system.
Edit Motor Calibration Offsets

Post Assessment
&
Evaluation

For Emergency Service, Spare Parts, Tech
Support, Questions, Comments, Complaints….
+603 5628 4888

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