ABB IRC5 with FlexPendant Operating Manual Download

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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

6.3.1 Present operating mode

Continued

Summary of Contents for IRC5 with FlexPendant

Page 1: ...ROBOTICS Operating manual IRC5 with FlexPendant ...

Page 2: ...Trace back information Workspace R18 2 version a9 Checked in 2018 10 09 Skribenta version 5 3 008 ...

Page 4: ...to persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained from ABB Original instruction...

Page 5: ...6 2 2 The IRC5 controller 37 2 3 The FlexPendant 43 2 4 The T10 45 2 5 RobotStudio Online 47 2 6 RobotStudio 48 2 7 When to use different jogging devices 51 2 8 Buttons and ports on the controller 53 3 Navigating and handling FlexPendant 53 3 1 About this chapter 54 3 2 The Main menu 54 3 2 1 HotEdit menu 56 3 2 2 FlexPendant Explorer 57 3 2 3 Inputs and Outputs I O 58 3 2 4 Jogging 60 3 2 5 Produ...

Page 6: ... 2 4 Configuring Most Common I O 115 3 7 2 5 Changing language 116 3 7 2 6 Changing programmable keys 118 3 7 2 7 Calibrating the touch screen 121 4 Jogging 121 4 1 Introduction to jogging 123 4 2 Coordinate systems for jogging 129 4 3 Joystick directions 130 4 4 Restrictions to jogging 131 4 5 Coordinated jogging 132 4 6 Basic settings for jogging 132 4 6 1 Selecting mechanical unit for jogging 1...

Page 7: ...ing instruction by instruction 217 5 9 Service routines 217 5 9 1 Running a service routine 221 5 9 2 Battery shutdown service routine 222 5 9 3 Calibration Pendulum CalPendulum service routine 223 5 9 4 Service Information System ServiceInfo service routine 224 5 9 5 LoadIdentify load identification service routine 233 5 9 6 Brake check service routine 241 6 Running in production 241 6 1 Basic pr...

Page 8: ...80 7 4 1 Safety I O signals 283 8 Handling the event log 283 8 1 Accessing the event log 284 8 2 Deleting log entries 285 8 3 Saving log entries 287 9 Backup and restore 287 9 1 Back up the system 289 9 2 Important when performing backups 291 9 3 Restore the system 295 10 Calibrating 295 10 1 How to check if the robot needs calibration 296 10 2 Updating revolution counters 299 Index 8 Operating ma...

Page 9: ... the FlexPendant s user interface and basic procedures Navigating and handling the FlexPendant 3 Procedures for jogging Jogging 4 Procedures for programming and testing including descriptions of some concepts for programming Programming and testing 5 Procedures for running in production Running in production 6 Procedures for handling I O Handling inputs and out puts I O 7 Procedures for the event ...

Page 10: ...es and stand alone controller 3HAC050798 001 Application manual Controller software IRC5 3HAC050961 001 Application manual MultiMove Note The document numbers that are listed for software documents are valid for RobotWare 6 Equivalent documents are available for RobotWare 5 Revisions Description Revision Released with RobotWare 6 0 Released with RobotWare 6 02 Added information about time limitati...

Page 11: ...ction Brake check service routine on page 233 Updated the section Backup and restore on page 287 Updated the section Example of backward execution on page 215 Updated the section Controller settings on page 112 E Released with RobotWare 6 07 Safety section restructured FlexPendant Home Screen background image is updated Updated the section When is backup possible on page 289 Updated the section Lo...

Page 12: ...g Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application manua...

Page 13: ... manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters Operating manual IRC5 with FlexPendant 13 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved Product documentation Continued ...

Page 14: ...This page is intentionally left blank ...

Page 15: ...oes not cover how to design for safety nor how to install safety related equipment These topics are covered in the Product Manuals supplied with the robot Note The integrator is responsible for the safety of the final application Operating manual IRC5 with FlexPendant 15 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 1 Safety 1 1 About this chapter ...

Page 16: ...1 2015i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10 2014ii Safety of machinery Electrical equipmen...

Page 17: ...IA R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Operating manual IRC5 with FlexPendant 17 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 1 Safety 1 2 Applicable standards Continued ...

Page 18: ...y stop button on the controller is located on the front of the cabinet However this can differ depending on your plant design The FlexPendant also has an emergency stop button Other emergency stop devices The plant designer may have placed additional emergency stop devices in convenient places Consult your plant or cell documentation to find out where these are placed 18 Operating manual IRC5 with...

Page 19: ...se of injury always make sure these are treated first Select fire extinguisher Always use carbon dioxide extinguishers when extinguishing fires in electrical equipment such as the robot or the controller Do not use water or foam Operating manual IRC5 with FlexPendant 19 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 1 Safety 1 3 2 Extinguishing fires ...

Page 20: ...st burn injuries or other severe injuries To avoid these personal injuries switch off the main power on the controller before proceeding work Note Switch off all main power switches in a MultiMove system 20 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 1 Safety 1 3 3 Make sure that the main power has been switched off ...

Page 21: ...p equipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The hold to run ...

Page 22: ...ices where you pull the button to release the latch Reset automatic emergency stop devices All automatic emergency stop devices also have some kind of latching feature that must be released Consult your plant or cell documentation to see how your robot system is configured Recover from emergency stops Action Make sure the hazardous situation that resulted in the emergency stop condition no longer ...

Page 23: ...ulator switches to the MOTORS OFF state To ensure safe use of the teach pendant the following must be implemented The enabling device must never be rendered inoperational in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move Anyone entering the working space of the robot must always hold the teach pendant This is to prevent...

Page 24: ... position enabling device and emergency stop work and are not damaged When not using the device hang it on the wall bracket provided for storage so it does not accidentally fall Always use and store the FlexPendant in such a way that the cable does not become a tripping hazard Never use sharp objects such as screwdriver or pen for operating the touch screen This could damage the touch screen Inste...

Page 25: ...t the emergency stop button to make sure it works if a custom connection cable is used Waste disposal Observe the national regulations when disposing of electronic components When replacing components dispose of used components properly Foreseeable misuse of three position enabling device Foreseeable misuse means that it is not allowed to jam the three position enabling device in the enabling posi...

Page 26: ...cy stop and safeguarding mechanisms are supervised so that any failure is detected by the controller and the robot is stopped until the problem is solved Built in stop functions The controller continuously monitor hardware and software functionality If any problems or errors are detected the robot is stopped until the problem has been solved then If the failure is a simple program stop is issued S...

Page 27: ... 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 disturban...

Page 28: ... care must be taken by the personnel preparing the manipulator in close proximity to the running conveyor A welding manipulator needs maintenance Taking the welding manipulator out of production also means that a work bench as well as a material handling manipulator must be taken out of production to avoid personnel hazards 28 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyri...

Page 29: ...ING 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 m...

Page 30: ...abling device and the Start button This hold to run function also applies when stepping through a program in manual full speed mode The three position enabling device is designed so that its push button must be pressed just half way to activate the motors of the manipulator Both in its all out and full in positions the manipulator will not move The hold to run function The hold to run function all...

Page 31: ... 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 Operating manual IRC5 with FlexPendant 31 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 1 Safety 1 4 4 About the manual m...

Page 32: ...tions are not followed that can lead to serious injury pos sibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING Warns for electrical hazards which could result in severe personal injury or death ELECTRI...

Page 33: ...ditions NOTE Describes where to find additional information or how to do an operation in an easier way TIP Operating manual IRC5 with FlexPendant 33 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 1 Safety 1 5 1 Safety signals in the manual Continued ...

Page 34: ...The protective stops and emergency stops are described in the product manual for the controller 34 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 1 Safety 1 5 2 Protective stop and emergency stop ...

Page 35: ...er mechanical units There may also be process equipment and additional software options This manual describes a basic robot without options However in a few places the manual gives an overview of how options are used or applied Most options are described in detail in their respective application manual Operating manual IRC5 with FlexPendant 35 3HAC050941 001 Revision G Copyright 2018 ABB All right...

Page 36: ... extra drive module must be added for each additional robot However a single control module is used Related information Product manual IRC5 IRC5 of design M2004 Product manual IRC5 IRC5 of design 14 Product manual IRC5 Panel Mounted Controller IRC5 of design M2004 Product manual IRC5 Panel Mounted Controller IRC5 of design 14 Product manual IRC5 Compact IRC5 of design M2004 Product manual IRC5 Com...

Page 37: ...r oil and accidental welding splashes The FlexPendant consists of both hardware and software and is a complete computer in itself It is connected to the robot controller by an integrated cable and connector The hot plug button option makes it possible to disconnect the FlexPendant in automatic mode and continue running without it Main parts These are the main parts of the FlexPendant xx1400001636 ...

Page 38: ...Close the protective cap on the USB port when not used Stylus pen The stylus pen included with the FlexPendant is located on the back Pull the small handle to release the pen Use the stylus pen to tap on the touch screen when using the FlexPendant Do not use screw drivers or other sharp objects Reset button If the FlexPendant freezes during operation press the reset button to restart the FlexPenda...

Page 39: ...reorient or linear F Toggle motion mode axis 1 3 or axis 4 6 G Toggle increments H Step BACKWARD button Executes one instruction backward as button is pressed J START button Starts program execution K Step FORWARD button Executes one instruction forward as button is pressed L STOP button Stops program execution M Continues on next page Operating manual IRC5 with FlexPendant 39 3HAC050941 001 Revis...

Page 40: ...e the other hand performs operations on the touch screen A left hander however can easily rotate the display through 180 degrees and use his right hand to support the device en0400000913 Continues on next page 40 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 2 Welcome to IRC5 2 3 The FlexPendant Continued ...

Page 41: ...t menu F Main menu The following items can be selected from the Main menu HotEdit Inputs and Outputs Jogging Production Window Program Editor Program Data Backup and Restore Calibration Control Panel Event Log Continues on next page Operating manual IRC5 with FlexPendant 41 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 2 Welcome to IRC5 2 3 The FlexPendant Continued ...

Page 42: ...tors on off program state and so on This is described in section Status bar on page 77 Close button Tapping the close button closes the presently active view or application Task bar You can open several views from the Main menu but only work with one at a time The task bar displays all open views and is used to switch between these Quickset menu The quickset menu provides settings for jogging and ...

Page 43: ...in horizontal direction etc This is achieved thanks to the built in inertial measurement unit consisting of accelerometers and gyroscopes which measure the motion of the device in space The joystick is used for adjusting the jog speed and the positive or negative direction The forward and backward movement of the joystick corresponds directly to the movement of the manipulator which is the most in...

Page 44: ...oystick B Emergency stop button C Three position enabling device D 44 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 2 Welcome to IRC5 2 4 The T10 Continued ...

Page 45: ...ertain functionality such as entering manual mode and enabling power to the mechanical unit motors you need a safety device that is connected to the robot using the same plug that alternatively is used to connect the FlexPendant The following RobotStudio Online apps are available in the Microsoft Windows Store Note You must have Windows 8 1 to run these Apps Description RobotStudio Online Apps Man...

Page 46: ...sed in production to view the program code xx1400002511 YuMi is a tool for programming of the new dual arm and collaborative robot YuMi IRB 14000 from ABB xx1500000832 It will help the users to get a fast introduction to robot programming using lead thru and graphical programming 46 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 2 Welcome to...

Page 47: ...dd ins are developed using the RobotStudio SDK With the SDK it is also possible to develop custom SmartComponents which exceed the functionality provided by RobotStudio s base components For more information see Operating manual RobotStudio RobotStudio for real controllers RobotStudio allows for example the following operations when connected to a real controller Installing and modifying systems o...

Page 48: ...ap Restart then Advanced Shut down the controller The FlexPendant Shut down the main computer Run and control robot programs Use To The FlexPendant or T10 Jog a robot The FlexPendant RobotStudio or RobotStudio Online Apps Start or stop a robot program The FlexPendant RobotStudio or RobotStudio Online Apps Start and stop background tasks Communicate with the controller Use To The FlexPendant or Rob...

Page 49: ...he FlexPendant or T10 with a combination of suitable Ro botStudio Online Apps Modify robot positions Configure the robot s system parameters Use To RobotStudio FlexPendant or the RobotStu dio Online Apps Edit the system parameters of the running system RobotStudio FlexPendant or the RobotStu dio Online Apps Save the robot s system parameters as config uration files RobotStudio FlexPendant or the R...

Page 50: ...ocument number for details see manual Recommended use 3HAC050941 001 Operating manual IRC5 with Flex Pendant FlexPendant 3HAC032104 001 Operating manual RobotStudio RobotStudio 3HAC050943 001 Operating manual IRC5 with T10 T10 50 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 2 Welcome to IRC5 2 7 When to use different jogging devices Contin...

Page 51: ...d Controller and if there is an external operator s panel xx0600002782 Main switch A Emergency stop B Motors on C Mode switch D Safety chain LEDs option E Service port for PC option G Duty time counter option H Service outlet 115 230 V 200 W option J Hot plug button option K Connector for FlexPendant or T10 L Related information Product manual IRC5 IRC5 of design 14 Continues on next page Operatin...

Page 52: ...14 Product manual IRC5 Compact IRC5 of design 14 Operating manual Troubleshooting IRC5 52 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 2 Welcome to IRC5 2 8 Buttons and ports on the controller Continued ...

Page 53: ...ical touch screen and how to use the filtering function How to log on and log off is also described Handling and troubleshooting the FlexPendant How to handle and clean the FlexPendant is described in Handling of FlexPendant on page 24 Troubleshooting the FlexPendant is described in Operating manual Troubleshooting IRC5 Hardware and software options Note that this manual covers only the views of a...

Page 54: ... tree view Select one or several positions to be tuned by tapping the arrow Notice that if a po sition is used at several places in your program any change made to the offset will take effect everywhere it is used Programmed targets Lists all selected positions and their current offset To remove a position from the selection you tap it and then tap the trash Selected targets Saves and loads select...

Page 55: ...values will be used immediately by a running program once the Apply button has been tapped Before you start using the HotEdit functionality it is strongly recommended to read Tuning positions with HotEdit on page 268 where HotEdit limitations and procedures as well as the baseline concept is detailed Related information See section Modifying and tuning positions on page 263 for a general overview ...

Page 56: ... en0400001130 Simple view Tap to hide type in the file window A Detailed view Tap to show type in the file window B Path Displays folder paths C Menu Tap to display functions for file handling D New folder Tap to create a new folder in current folder E Up one level Tap to change to parent folder F Refresh Tap to refresh files and folders G 56 Operating manual IRC5 with FlexPendant 3HAC050941 001 R...

Page 57: ...vice that is connected to an industrial network within the robot system real I O signal An I O signal without a representation on any industrial network I O device virtual I O signal By specifying an I O signal a logical representation of the real or virtual I O signal is created The I O signal configuration defines the specific system parameters for the I O signal that will control the behavior o...

Page 58: ...y On is displayed Absolute accuracy Select motion mode described in section Selecting motion mode on page 134 Motion mode Select coordinate system described in section Selecting coordinate system on page 138 Coordinate system Select tool described in section Selecting tool work object and payload on page 135 Tool Select work object described in section Selecting tool work object and payload on pag...

Page 59: ...e section Updating revolution counters on page 296 Select position format described in section Reading the exact position on page 143 Position format Displays current joystick directions depending on setting in Motion mode See section Selecting motion mode on page 134 Joystick directions Align the current tool to a coordinate system See section Aligning tools on page 145 Align Move the robot to a ...

Page 60: ...ing positions in the Program Editor or Production Window on page264 Show Motion Pointerand Show Program Pointer see About the Program and Motion Pointers on page 167 Edit Program see Program Editor on page 63 Note The Visual Step mode icon indicates that the Step Into mode is not selec ted This means that if the step mode is Step Out Step Over or Next Move the Visual Step mode icon is displayed De...

Page 61: ...m Data This section illustrates the Program Data view en0400000659 Changes scope of data types in the list see Viewing data in specific tasks modules or routines on page 168 Change Scope Shows all instances of the selected data type Show Data Shows all or only used data types View Continues on next page Operating manual IRC5 with FlexPendant 61 3HAC050941 001 Revision G Copyright 2018 ABB All righ...

Page 62: ... selected data type see Creating new data instance on page 169 New Edits the selected instances see Editing data instances on page171 Edit Refreshes the list of instances Refresh Returns to the Program Data menu View Data Types 62 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 2 6 Program Data Continue...

Page 63: ...ll routines see Handling of routines on page 157 Routines Opens instruction menu see Handling of instructions on page162 Add Instruction Opens edit menu see Handling of instructions on page 162 Edit Functions for moving the program pointer service routines etc see Running a service routine on page217 and About the Program and Motion Pointers on page 167 Debug Functions to search routines and view ...

Page 64: ... 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 Edito...

Page 65: ...287 Illustration of Backup and Restore This is the Backup and Restore menu xx0300000440 See Back up the system on page 287 Backup Current System See Restore the system on page 291 Restore System Operating manual IRC5 with FlexPendant 65 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 2 8 Backup and Restore ...

Page 66: ...anual 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 Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 2 9 Calibration ...

Page 67: ...s the Calibration menu options after selecting mechanical unit en0400000771 Operating manual IRC5 with FlexPendant 67 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 2 9 Calibration Continued ...

Page 68: ...tains functions for customizing the robot system and the FlexPendant Continues on next page 68 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 2 10 Control Panel ...

Page 69: ...guage Settings for the four programmable keys on the FlexPendant See Changing programmable keys on page 116 ProgKeys Settings for configuring the network the date and time for the robot controller and the ID of the controller See Controller set tings on page 112 Controller Settings Recalibration settings for the touch screen See Calibrating the touch screen on page 118 Touch Screen Configuration o...

Page 70: ...t may be performed with the event log xx0300000447 Description Function Tap the message The message structure is described in An event log message on page 71 View a message See Scrolling and zooming on page 92 Scroll or zoom a message See Deleting log entries on page 284 Delete the log See Saving log entries on page 285 Save the log See Accessing the event log on page 283 Close the log Continues o...

Page 71: ... stop caused by the particular event Intended to assist in understanding the causes and implications of the event E Probable causes A list of probable causes listed in order of probability F 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 proble...

Page 72: ...ctions List of installed systems 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 Name and key of the Control Module Control module Installed RobotWare options and languages Options Lists all Drive Modules Drive modules Name and key of Drive Module x Drive module x Drive Module x opti...

Page 73: ...ard Drive module x Lists the data of Robots or external axes connected to the con troller Mechanical units Software resources It contains information about the RAPID When the Software resources is expanded the following are visible Contains information about system uptime and memory System Software used by the controller RAPID Memory allocated for RAPID programs RAPID memory Shows the execution lo...

Page 74: ... 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 Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 2 13 Restart ...

Page 75: ...out 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 75 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 2 14 Log Off ...

Page 76: ...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 Clears all messages Clear Clears all messages Don t Show Logs Hides task names Don t Show Task Name 76 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigat...

Page 77: ...de B System name and controller name C Controller state D Program state E 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 F Operating manual IRC5 with FlexPendant 77 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 4 Stat...

Page 78: ...lustration of the Quickset menu This section describes the buttons in the Quickset menu en0300000471 Mechanical unit see Quickset menu Mechanical unit on page 79 A Increment see Quickset menu Increment on page 84 B Run Mode see Quickset menu Run Mode on page 85 C Step Mode see Quickset menu Step Mode on page 86 D Speed see Quickset menu Speed on page 87 E Tasks see Quickset menu Tasks on page 88 F...

Page 79: ...on page 81 D Work object settings work object 0 currently selected further settings are de scribed in Illustration Work object settings on page 81 E Coordinate system settings world coordinate currently selected further settings are described in Illustration Coordinate system settings on page 82 F Turn coordination off further settings are described in Turn coordination off on page 83 G Show detai...

Page 80: ...le 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 Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 5 2 Quickset menu Mechanical unit Continued ...

Page 81: ...k 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 Continues on next page Operating manual IRC5 with FlexPendant 81 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 5 2 Qui...

Page 82: ...indow 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 Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 5 2 Quickset menu Mechanical uni...

Page 83: ...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 coord...

Page 84: ...ncrements None Small movements Small Medium movement Medium Large movements Large User defined movements User Displays hides increment values Show Hide Values Defines the unit for the angles Angle unit Note The Increment menu is available only in manual mode 84 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPend...

Page 85: ...troller software IRC5 section Multitasking MultiMove see Application manual MultiMove section User interface specific for Multimove Illustration Run mode en0300000472 Runs one cycle then stops execution Single Cycle Runs continuously Continuous Operating manual IRC5 with FlexPendant 85 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 5 4 Quic...

Page 86: ...h the current routine was called Not possible to use in the Main routine Step Out Called routines are executed in one single step Step Over Steps to the next move instruction Stops before and after movement in structions for example to modify positions Next Move 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 s...

Page 87: ...unning speed in relation to max is displayed above the buttons en0300000470 Decrease running speed in steps of 1 1 Increase running speed in steps of 1 1 Decrease running speed in steps of 5 5 Increase running speed in steps of 5 5 Set speed to 0 0 Run at quarter speed 25 25 Run at half speed 50 50 Run at full speed 100 100 Operating manual IRC5 with FlexPendant 87 3HAC050941 001 Revision G Copyri...

Page 88: ... 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 disp...

Page 89: ...rs 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 Continues on next page Operating manual IRC5 with FlexPendant 89 3HAC...

Page 90: ... move xx0300000492 backward xx0300000493 forward 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 Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 6 1 Using the soft keyboard Continued ...

Page 91: ...y 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 man...

Page 92: ... Program Editor en0400000685 Zoom in larger text A Scroll up the height of one page B Scroll up the height of one line C Scroll left D Scroll right E Zoom out smaller text F Scroll down the height of one page G Scroll down the height of one line H 92 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 6 3 S...

Page 93: ...ration 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 Illustrati...

Page 94: ...string Reset Depending on type of data there may be one or several ways to filter data e g numeric alphabetic 123 ABC Applies the filter Filter Opens and closes the Active filter menu en1100000506 Continues on next page 94 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 6 4 Filtering data Continued ...

Page 95: ... controlling when the filter dialog should appear 1 Enter a new number defining the upper limit for not using the filter Then tap Done 2 Tap Virtuals to select if all or only virtual or only non virtual signals should be listed 3 Operating manual IRC5 with FlexPendant 95 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 6 4 Filtering data Cont...

Page 96: ...process application to start 2 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 en0400000768 The views and process application running in this case are FlexPendant Explorer view A Program Editor view B RobotWare Arc a process application C Control Pane...

Page 97: ...ge is displayed on the FlexPend ant Decide whether to grant or reject access 1 If you want to grant access then tap Grant The user holds write access until he dis connects 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 2 Note For a system connected to T10 users in RobotStudio can request write access by pres...

Page 98: ...tion If you select Default User then no pass word is required and you are logged on automatically Tap on the User menu and select a user If there are more than seven users then the menu is replaced with a button 1 If the user you have chosen has a pass word you must use the soft keyboard to enter password Tap ABC to display the soft keyboard 2 Enter the password and tap OK TapLogin 3 Continues on ...

Page 99: ...o 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 page101 Operating manual IRC5 with FlexPendant 99 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 6 7 Logging on and off Continued ...

Page 100: ...otStudio 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 1 Tap File System Default Path en0500002361 2 Tap the File type menu to choose type of default path RAPID programs RAPID modules Configurations files 3 Type the default path or tap Browse to choose the desired location 4 If required ...

Page 101: ... 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 th...

Page 102: ...f Changing background image Use this procedure to change background image on FlexPendant Action On the ABB menu tap Control panel 1 Tap FlexPendant and then Background Image en0500001547 2 Tap Browse to locate another picture on the controller hard disk 3 Tap Default to restore the original background image 4 Tap OK 5 102 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2...

Page 103: ... Operating manual RobotStudio Defining visibility level for UAS protected functions Action On the ABB menu tap Control Panel and then tap FlexPendant 1 Tap User Authorization System en0400001153 2 Tap to select the level of visibility for UAS protected functions Hide non accessible functions OR Show message when trying to access protected functions 3 Tap OK 4 Operating manual IRC5 with FlexPendant...

Page 104: ... this procedure to define an additional test view Action On the ABB menu tap Control Panel and then FlexPendant 1 Tap Additional Test View The displayed screen might look like this en0600003110 2 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 use...

Page 105: ...f 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 namin...

Page 106: ...ple 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...

Page 107: ...e 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 1 Tap Task Panel Settings 2 Select Only Normal tasks or All tasks 3 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 ...

Page 108: ...000330 Select a controller and system naming option according to your requirement 3 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 n...

Page 109: ... 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 3 Tap OK to use the new brightness and contrast levels 4 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 Ch...

Page 110: ...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 1 Tap Ap...

Page 111: ... automatically Jogging directions See buttons A G in the illustra tion Hard buttons on page39 Start Stop Forward and Backward buttons do not change place with program mable keys Hardware buttons and pro grammable keys Differently located at the bot tom instead of at the top No effect Emergency stop No effect Three position enabling device Operating manual IRC5 with FlexPendant 111 3HAC050941 001 R...

Page 112: ...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 Action Step On the ABB menu tap Control Panel 1 Tap Controller Settings 2 Navigate to the bottom menu tap Settings and select Network The Control Panel Controller Settings Network window is displayed 3 Configure the network settings according to yo...

Page 113: ...5 The name of the controller is saved Operating manual IRC5 with FlexPendant 113 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 7 2 3 Controller settings Continued ...

Page 114: ...onfigure the list Most Common I O Action On the ABB menu tap Control Panel 1 Tap I O A list of all I O signals defined in the system is listed with check boxes 2 Tap the names of the signals to select for the Most Common I O list 3 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 4 ...

Page 115: ...bles 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 1 Tap Language A list of all installed languages is displayed 2 Tap the language that you want to change to 3 Tap OK A dialog box is displayed Tap Yes to proceed and restart the FlexPendant The current language is replaced by th...

Page 116: ...gKeys en0400001154 2 Select key to set Key 1 4 in the upper selection list 3 Tap the Type menu to select type of action None Input Output System 4 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 onl...

Page 117: ...nal 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 6 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 7 Set the other keys as described in steps 3 to 7 above 8 Tap OK to save th...

Page 118: ...w seconds A series of symbols will appear on the screen one at a time 3 CAUTION Do not use a sharp object which can damage the surface of the screen Tap the center of each symbol with a pointed object 4 The recalibration is complete 5 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 relea...

Page 119: ... 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 119 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 3 Navigating and handling FlexPendant 3 7 2 7 Calibrating the touch screen Continued...

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Page 121: ...8 How to jog the robot axis by axis is detailed in section Jog axis by axis on page 137 Select a mechanical unit The axes can be jogged in different ways 3 The robot s working range is defined by system parameters See Technical refer ence manual System parameters Define the working range for the robot ro bots as well as for any other pieces of equipment working in the robot cell 4 The FlexPendant ...

Page 122: ...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...

Page 123: ...es 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...

Page 124: ...t 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 Copyright 2018 ABB All rights reserved 4 Jogging 4 2 Coordinate systems for jogging Continued ...

Page 125: ... 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 Continues on nex...

Page 126: ...e 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 w...

Page 127: ...ed 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 b...

Page 128: ...rdinate system coincides with the base coordinate system Examples of use For example you have two robots one floor mounted and one inverted The base coordinate system for the inverted robot would be upside down If you jog in the base coordinate system for the inverted robot movements will be very difficult to predict Choose the shared world coordinate system instead 128 Operating manual IRC5 with ...

Page 129: ...irections depends on the selected motion mode Description Illustration joystick Motion mode Linear mode is described in sec tion Setting the tool orientation on page 136 en0400001131 Linear Axis 1 3 mode is described in section Jog axis by axis on page 137 en0300000536 Axis 1 2 and 3 default for robots Axis 4 6 mode is described in section Jog axis by axis on page 137 en0300000537 Axis 4 5 and 6 R...

Page 130: ...sonnel 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...

Page 131: ...hanical unit 1 See Selecting coordinate system on page 138 Set Coordinate system to Work Object 2 See Selecting tool work object and pay load on page 135 Set Work object to the work object moved by the other mechanical unit 3 Any jogging while this mechanical unit is selected will also affect the robot that is coordinated with it Select the mechanical unit that moves the work object 4 Coordinating...

Page 132: ...presented 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 me...

Page 133: ...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 Program Editor on page 63 Mechanical units can be activated or deactivated with the Activate function in the Jogging wi...

Page 134: ...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 tapJogging 1 Tap Motion mode 2 The significance of the joystick directions are shown in Joystick direction after making the selection Tap on the mode you want and then tap OK 3 Related information Joystick directions on pag...

Page 135: ...ing 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 1 Tap Tool Work object or Payload to display the lists of available tools work objects or payloads 2 Tap the tool work object or payload of choice followed by OK 3 Operating manual IRC5 with FlexPendant 135 3HAC050941 001 Revision...

Page 136: ... 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 1 Tap Motion Mode then tap Reorient followed by OK 2 If not already selected select the proper tool by following the procedure in Selecting tool work object and payload on page 135 3 Press an...

Page 137: ... 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 1 Tap Motion Mode 2 Tap on the axis ...

Page 138: ...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 ...

Page 139: ... to view jogging properties 1 Tap Joystick lock to check the joystick properties or check the Joystick directions area properties in the right hand corner of the window 2 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 ABBmenu tap Jogging 1 Tap Joystick lock en0300000488 2...

Page 140: ...stick directions lock Action On the ABB menu tap Jogging 1 Tap Joystick lock 2 Tap None then tap OK 3 140 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 4 Jogging 4 6 7 Locking the joystick in specific directions Continued ...

Page 141: ... Using thee Jogging window on the ABB menu Using the Quickset menu Increments see Quickset menu Increment on page 84 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 sel...

Page 142: ...zes Choose between small medium or large increments You can also define your own increment movement sizes Angular Distance Increment 0 005 0 05 mm Small 0 02 1 mm Medium 0 2 5 mm Large User 142 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 4 Jogging 4 6 8 Incremental movement for precise positioning Continued ...

Page 143: ...sitions 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 coordina...

Page 144: ...t 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 Copyright 2018 ABB All rights reserved 4 Jogging 4 6 9 Readin...

Page 145: ...ligning mechanical units This procedure describes how to align tools Action On the ABB menu tap Jogging 1 Make sure that the right tool is active and then tap Align en0500001548 2 Select a coordinate system to align the selected tool to 3 Press and hold the three position enabling device and then tap and hold Start Align to start aligning the tool 4 Tap Close when completed 5 Operating manual IRC5...

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Page 147: ...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 ...

Page 148: ...ndlers are described in the RAPID manuals In order to deal with potential errors that may occur during program execution you may want to create an error handler 6 Proceed as detailed in section Testing on page 206 After completing the actual RAPID pro gram it will require testing before being put into production 7 How to modify positions while the program is running is described in section HotEdit...

Page 149: ...been loaded you may start program execution 3 Proceed as detailed in section Stopping programs on page 244 After program execution is completed the program may be stopped 4 Operating manual IRC5 with FlexPendant 149 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Programming and testing 5 2 Using RAPID programs Continued ...

Page 150: ...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 pr...

Page 151: ...p OK The program is loaded and the program code is displayed en0400000699 4 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 1 Tap Tasks and Programs 2 Tap File and select Save Program...

Page 152: ...f the program Then tap OK 4 Deleting a program This section describes how to delete a program Action On the ABB menu tap Program Editor 1 Tap Tasks and Programs 2 Tap File and select Delete Program A confirmation dialog is displayed 3 Tap OK to delete or Cancel to keep the program intact 4 152 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5...

Page 153: ...es 2 Tap File then tap New Module en0400000688 3 Tap ABC and use the soft keyboard to enter the new module s name Then tap OK to close the soft keyboard 4 Select which type of module to be created Program System Then tap OK 5 How to later switch between these types is detailed in section Changing type of module on page 155 Continues on next page Operating manual IRC5 with FlexPendant 153 3HAC05094...

Page 154: ...fined as detailed in section Setting default paths on page 100 3 Tap OK to load the selected module The module is loaded 4 Saving a module This section describes how to save a module Action On the ABB menu tap Program Editor 1 Tap Modules and tap to select the module you want to load 2 Continues on next page 154 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB Al...

Page 155: ...e This section describes how to rename a module Action On the ABB menu tap Program Editor 1 Tap Modules 2 Tap File then Rename Module The soft keyboard is displayed 3 Use the soft keyboard to enter the module s name Then tap OK 4 Changing type of module This section describes how to change the type of module Action On the ABB menu tap Program Editor 1 Tap Modules and select the module to be change...

Page 156: ...dule you want to delete 2 Tap File then Delete Module A dialog box is displayed 3 Tap OK to delete the module without saving it 4 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 Copyright 2018 ABB All rights reserved 5 Programming ...

Page 157: ...on values en0400000692 3 Tap ABC and use the soft keyboard to enter the new routines name Then tap OK 4 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 5 Do you need to use any parameters 6 If YES tap and proceed as detailed in section Defining parameters in routine on page 1...

Page 158: ...utine 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 1 Continues on next page 158 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Programming and testing 5 3 3 Handling of routines Continued ...

Page 159: ... parameters in the RAPID reference manuals en0400000695 2 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 3 Tap to select a parameter To edit values tap the value 4 Continues on next page Operating manual IRC5 with FlexPendant 159 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Programming and t...

Page 160: ...Routines 2 Highlight the routine by tapping it 3 Tap File then Change Declaration 4 Change any declaration values for the routine Then tap OK 5 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 1 Tap Routines 2 Highlight the routine by tapping it ...

Page 161: ...aving any changes made to it Cancel to revert without deleting the routine 5 Operating manual IRC5 with FlexPendant 161 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Programming and testing 5 3 3 Handling of routines Continued ...

Page 162: ...ruction under which you want to add a new instruction 2 Tap Add instruction A category of instructions is displayed en0400000697 A large number of instructions divided into several categories are available The de fault 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...

Page 163: ...ction describes how to edit instruction arguments Action Tap the instruction to edit en0400000699 1 Tap Edit en0400000701 2 Continues on next page Operating manual IRC5 with FlexPendant 163 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Programming and testing 5 3 4 Handling of instructions Continued ...

Page 164: ...tiple argument instructions en0400000702 3 Tap the argument to be changed A number of options are displayed en0400000703 4 Tap an existing data instance to select and then tap OK to complete or tap Expression 5 Continues on next page 164 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Programming and testing 5 3 4 Handling of instructions C...

Page 165: ...struction This section describes how to cut an instruction Action Tap to select the instruction you want to cut 1 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 2 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...

Page 166: ...o jog in a square Jog the robot to the first point 1 In the program editor tap Add Instruction 2 Tap MoveL to insert a MoveL instruction 3 Repeat for the next four positions of the square 4 For the first and last instruction Tap z50 in the instruction tap Edit and then Change selected to Fine Tap OK 5 Result Your program code should look like this Proc main MoveL v50 fine tool0 MoveL v50 z50 tool0...

Page 167: ...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 betw...

Page 168: ...e 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 3 Tap OK to confirm your choice 4 Tap twice to select a data type and vie...

Page 169: ...l reachable within the module Task reachable within the task 5 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 6 Tap the Module menu to select module 7 Tap the Routine menu to select routine 8 If you want to create an array of data i...

Page 170: ...Action Tap OK 10 170 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Programming and testing 5 4 2 Creating new data instance Continued ...

Page 171: ...instance you want to edit and then tap Edit en0400000671 3 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 a...

Page 172: ...ID Overviewfor 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 1 Tap Yes if you are sure the data instance is to be deleted 2 CAUTI...

Page 173: ...s 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 1 Defining a data instance How to define the tool frame or work object frame is described in the sections Defining the tool frame on page180 a...

Page 174: ...bout 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 Copyright 2018 ABB All rights reserved 5 Programming and testing 5 4 3 Editing da...

Page 175: ...ple 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 an...

Page 176: ...finitions but only one can be active at any one time There are two basic types of TCPs moveable or stationary Moving TCP 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 Stationar...

Page 177: ...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 175and What is the tool center point on page 176 A en0400000779 Tool center point TCP for tool0 A Action On the ABB menu ...

Page 178: ...ool after it is referenced in any program you must also change all occurrences of that tool tap button next to Name the name of the tool Tools should always be glob al as to be available to all modules in the program select the preferred scope from the menu the scope Tool variables must always be persistent the storage type select the module in which this tool should be declared from the menu the ...

Page 179: ...fined 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 179 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Programming and testing 5 5 3 Creating a tool Continued ...

Page 180: ...iffers is how the orientation is defined then select If you want to TCP default orient set the orientation the same as the orientation of the robot s mounting plate TCP Z set the orientation in Z axis TCP Z X set the orientation in X and Z axes 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 1 Tap T...

Page 181: ...esult you should be equally careful when defining all of them 6 See How to proceed with tool frame definition on page 182 for information on how to gather positions and perform the tool frame definition 7 Continues on next page Operating manual IRC5 with FlexPendant 181 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Programming and testing 5 5 4 Defining the tool frame Continue...

Page 182: ... best result Just changing the tool orientation will not give as good a result Repeat step 1 and 2 for each approach point to be defined positions B C and D 3 Follow the instructions in How to define elongator points on page 183 If the method you are using is TCP Z or TCP Z X orientation must be defined as well 4 If for some reason you want to redo the calibration procedure described in step 1 4 t...

Page 183: ...finition 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 posit...

Page 184: ...ction details how to display the tool data Action On the ABB menu tap Jogging 1 Tap Tool to display the list of available tools 2 Tap the tool you want to edit then tap Edit A menu appears 3 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 4 Proceed with changing the data as describe...

Page 185: ... axis for the tool you want to define Z 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 1 Measure the distance from the center of the robot s mounting flange to the tool s center point along the Y axis of tool0 2 Measure the distance from the center of the robot s mounting flange to the tool s center point along the Z ...

Page 186: ...tload cog z None tload aom q1 If necessary enter the orientation of the axis of moment 5 tload aom q2 tload aom q3 tload aom q4 kgm2 tload ix tload iy If necessary enter the tool s moment of inertia 6 tload iz Tap OK to use the new values Cancel to leave the definition unchanged 7 186 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Programm...

Page 187: ...A menu appears Change Declaration Change Value Delete Define 3 In the menu tap Change Declaration The tool s declaration appears 4 Edit the tool declaration as listed in section Creating a tool on page 177 5 Note If you change the name of a tool after it is referenced in any program you must also change all occurrences of that tool Operating manual IRC5 with FlexPendant 187 3HAC050941 001 Revision...

Page 188: ... For more information about deleting a tool see Deleting a data instance on page172 188 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Programming and testing 5 5 7 Deleting a tool ...

Page 189: ... 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 1 Tap the work object you want to edit then tap Edit A menu appears 2 In the menu tap Change value The data that defines the work object appears 3 Tap the instance robhold 4 Tap TRUE to indicate that this work object is held by the robot 5 Tap OK to use the new...

Page 190: ... 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 Copyright 2...

Page 191: ...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 mus...

Page 192: ...eate a new work object 3 Tap OK 4 Work object declaration settings Recommendation then If you want to change Work objects are automatic ally named wobj followed by a running number for ex ample wobj10 wobj27 You should change this to something more descriptive If you change the name of a work object after it is refer enced in any program you must also change all occur rences of that work object ta...

Page 193: ...ject 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 1 Tap Work object to display the list of available work objects 2 Tap the work object you want to define then tap Edit 3 In the menu tap Define 4 Select method from the User method and or ...

Page 194: ... more precise definition Press the three position enabling device and jog the robot to the first X1 X2 or Y1 point that you want to define 2 Select the point in the list 3 Tap Modify Position to define the point 4 Repeat steps 2 to 4 for the remaining points 5 Continues on next page 194 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Progra...

Page 195: ...hen 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 ...

Page 196: ...on In the Work Object Frame Definition dialog tap Positions and Load 1 Tap the module that holds the calibration points tap OK 2 If the controller finds all or any predefined positions in the module the positions are automatically loaded to the correct user or object point 3 In the Load dialog tap OK If some positions are missing or do not have the correct names the controller cannot load the posi...

Page 197: ...ing the work object coordinate system on page193 You can however edit the values manually using the guide below Unit Instance Values mm oframe trans x The cartesian coordinates of the position of the object frame oframe trans y oframe trans z oframe rot q1 The object frame orientation oframe rot q2 oframe rot q3 oframe rot q4 mm uframe trans x The cartesian coordinates of the position of the user ...

Page 198: ...u want to edit then tap Edit 3 In the menu tap Change Declaration 4 The work object s declaration appears 5 Edit the tool declaration as listed in section Creating a work object on page 192 6 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...

Page 199: ...For more information about deleting a work object see Deleting a data instance on page 172 Operating manual IRC5 with FlexPendant 199 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Programming and testing 5 6 6 Deleting a work object ...

Page 200: ...01 2 Tap New to create a new payload and enter the data See Payload declaration settings on page 201 3 Tap OK 4 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 fo...

Page 201: ...must al ways be persistent the storage type select the module in which this payload should be de clared from the menu the module 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 ...

Page 202: ...er the weight of the payload 1 mm load cog x Enter the payload s center of gravity 2 load cog y load cog z load aom q1 Enter the orientation of the axis of moment 3 load aom q2 load aom q3 load aom q3 kgm2 ix iy Enter the payload s moment of inertia 4 iz Tap OK to use the new values Cancel to leave the data unchanged 5 Using the PayLoadsInWristCoords parameter By using the PayLoadsInWristCoords pa...

Page 203: ...manual System parameters and Technical reference manual RAPID Instructions Functions and Data types Operating manual IRC5 with FlexPendant 203 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Programming and testing 5 7 2 Editing the payload data Continued ...

Page 204: ...ap the payload you want to edit then tap Edit 3 In the menu tap Change declaration 4 The payload s declaration appears See Creating a payload on page 200 5 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 Copyright 2018 ABB All rights reserv...

Page 205: ...For more information about deleting a payload see Deleting a data instance on page 172 Operating manual IRC5 with FlexPendant 205 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Programming and testing 5 7 4 Deleting a payload ...

Page 206: ...ecific 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...

Page 207: ...t be taken by the personnel preparing the manipulator in close proximity to the running conveyor A welding manipulator needs maintenance Taking the welding manipulator out of production also means that a work bench as well as a material handling manipulator must be taken out of production to avoid personnel hazards Operating manual IRC5 with FlexPendant 207 3HAC050941 001 Revision G Copyright 2018...

Page 208: ...ver 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 ...

Page 209: ...vice and the Start button This hold to run function also applies when stepping through a program in manual full speed mode The three position enabling device is designed so that its push button must be pressed just half way to activate the motors of the manipulator Both in its all out and full in positions the manipulator will not move The hold to run function The hold to run function allows stepp...

Page 210: ...tion 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 Copyright 2018 ABB All rights reserved 5 Programming and testing 5 8 2 About the...

Page 211: ...n this mode immediately stops ma nipulator 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 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 1 Choose executio...

Page 212: ... a specific instruction Action On the ABB menu tap Program Editor 1 Tap on the program step where you want to start then tap Debug and then PP to Cursor 2 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 3 Press the Start button on the FlexPendant see E in illustration...

Page 213: ...ving the program pointer Action On the ABB menu tap Program Editor 1 Tap Debug and then PP to Routine to place the program pointer at the start of the routine 2 Press the Start button on the FlexPendant 3 Related information How to run a service routine is described in Running a service routine on page217 The same method can be used to run a specific routine in the task scope See Running a service...

Page 214: ... 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...

Page 215: ...60 stepping forward until the robot is in p50 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 pressing the Back ward button once the robot will move to p40 linearly with the speed v300 pressing the Back ward button again The target for this movemen...

Page 216: ...bot will move linearly to p10 with the speed v1000 pressing the Back ward button again The motion pointer will indicate p10 and the program pointer will move up to MoveJ p10 the robot will not move but the program pointer will move to the next instruction MoveL p20 pressing the Forward button once the robot will move to p20 with the speed v1000 pressing the Forward button again 216 Operating manua...

Page 217: ...ally 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 resum...

Page 218: ...utines on the View menu to see all available routines en0400000885 Tap a service routine and then tap Go to 4 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 Copyright 2018 ABB All rights reserved 5 Programming and testing 5 9 1 Running a service ...

Page 219: ...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 M...

Page 220: ... see Technical reference manual RAPID Instructions Functions and Data types 220 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 5 Programming and testing 5 9 1 Running a service routine Continued ...

Page 221: ...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 ...

Page 222: ...he calibration equipment for Calibration Pendulum is delivered as a complete toolkit including the manual Operating manual Calibration Pendulum Related information Running a service routine on page 217 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...

Page 223: ...l 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 in...

Page 224: ...d 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 id...

Page 225: ...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 A B C 30 30 30 30 en0500001537 Configuration 1 start position A Configuration angle B Configu...

Page 226: ...able 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 resulti...

Page 227: ...How to start service routines is described in Running a service routine on page 217 Start LoadIdentify from the Program Editor Press the three position enabling device and then press the Start button on the FlexPendant 1 Tap Cancel and then Cancel Call Rout to quit the service routine without loosing the program pointer Tap OK to confirm that current path will be cleared and that the program point...

Page 228: ...ion move ments slowly before performing the load identification slow test Tap Yes if you want a slow test and No to proceed to the identification 10 The setup for load identification is now complete To start the motion switch to Automatic mode and Motors On Then tap Move to start the load identification movements 11 When the identification is finished switch back to manual mode press the three pos...

Page 229: ...dentification with cold motors no warm up Information Action How to start service routines is described in Running a service routine on page 217 Start LoadIdentify from the Program Editor Press the three position enabling device and then press the Start button on the FlexPendant 1 Tap Cancel and then Cancel Call Rout to quit the service routine without loosing the program pointer Tap OK to confirm...

Page 230: ...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 10 When the identification is finished switch back to manual mode press the three position enabling device and the Start button Tap OK to confirm 11 The result of the load identification is now presented on the FlexPendant Tap Tool if...

Page 231: ...or 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...

Page 232: ...n 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 Editing the tool data on page 184 and Editing the payload data on page 202 The product manual for the robot con...

Page 233: ...e 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 ax...

Page 234: ...enance type General Rapid topic Controller in Technical reference manual System parameters Event logs When BrakeCheck is executed the following event logs will be shown Title Event log Brake Check Done 10272 Brake Check Started 10273 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 Tit...

Page 235: ...nc2 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 calc...

Page 236: ...odule 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 HO...

Page 237: ...er_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 S...

Page 238: ...eCheck execution BrakeCheck test ER ROR Set to BrakeCheck test WARNING Set to BrakeCheck test OK Set to Signal 0 0 1 BCOK 1 0 0 BCERR 0 1 0 BCWAR 0 0 0 BCACT 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 Set to Signal 0 BCOK 0 BCACT During the first brake check test Signa...

Page 239: ... 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 l...

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Page 241: ...sonnel are inside the ro bot cell 2 xx0600002782 Select operating mode on the controller with the mode switch 3 C Motors on button D Mode switch Press the Motors on button on the control ler to activate the robot 4 How to load programs is described in sec tion Handling of programs on page 150 Is a program loaded If yes proceed to the next step 5 If no load a program See Quickset menu Run Mode on p...

Page 242: ...ppear to avoid restarting the program if the consequences are unknown then tap If you Yes 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 No Are unsure of the consequences your changes might have and want to investigate further Restart from the beginning A program can be restarted from...

Page 243: ...veral 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 243 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 6 Running in production 6 1 1 Starting pro...

Page 244: ...n or step by step execution When using hold to run or step by step execution execution can be stopped according to the following Information Action Mode The hold to run function is described in section The FlexPendant on page 37 Release the Start button Operation with hold to run The STOP and Forward but ton are described in section The FlexPendant on page 37 The robot will stop after ex ecuting e...

Page 245: ...d 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 multita...

Page 246: ...2 Tap the task into which you want to load a program 3 On the File menu tap Load Program 4 If you want to open a program in another folder locate and open that folder See de scription in FlexPendant Explorer on page 56 The file dialog box appears Tap the program you want to load followed by OK 5 Tap Close to close the Program Editor 6 Viewing multitasking programs In the Production Window there is...

Page 247: ...tem 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 pro...

Page 248: ...r more in formation see Setting sensitivity of Motion Supervision on page 249 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 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 super vision Note If the option Collision Detection is n...

Page 249: ...sed 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...

Page 250: ...oller 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 otherwi...

Page 251: ...Pendant 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 a...

Page 252: ...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 Copyright 2018 ABB All rights reserved 6 Running in production 6 1 5 Using the hot plug option Continued ...

Page 253: ...ich 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 ...

Page 254: ...g 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...

Page 255: ...ncel don t want to continue the program Operating manual IRC5 with FlexPendant 255 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 6 Running in production 6 2 2 Returning the robot to the path Continued ...

Page 256: ...type Mechanical Unit topic Motion to No 1 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 2 Deactivate the uncalibrated mechanical unit 3 Move the program pointer to Main otherwise the mechanical unit will be automatically activated 4 Run the service routine or other RAPID cod...

Page 257: ...de E Information Action detailed in Switching from manual to auto matic mode on page 259 To switch from manual to automatic mode 1 detailed in Switching from automatic to manual mode on page 261 To switch from automatic to manual mode 2 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 en...

Page 258: ...s active is highlighted F 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 Copyright 2018 ABB All rights reserved 6 Running in production 6 3 1 Present operating mode Continued ...

Page 259: ...OK to close the dialog 3 If you change the switch back to manual mode the dialog will be closed automatically How to start programs is de scribed in Starting programs on page 241 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 4 Note If your specific system uses a distributed operator s panel con...

Page 260: ...entation 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 Copyright 2018 ABB All rights reserved 6 Running in production 6 3 2 Switching f...

Page 261: ...edure is completed 2 If no try to locate the error 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 261 3HAC050941 001 Revision G Copyright 2...

Page 262: ...ed position 1 Error handling is detailed in Operating manual Troubleshooting IRC5 Did the system change mode without er rors If yes then this procedure is completed 2 If no try to locate the error 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...

Page 263: ...ns 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 instructi...

Page 264: ...9 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...

Page 265: ...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 par...

Page 266: ...ositions 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 pla...

Page 267: ...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 n...

Page 268: ...d select tuning mode linear reorient or external axes and then coordinate system tool or work object 2 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 3 To activate the new values tap APPLY The offset will be used directly if the program is running 4 If you are satisfied with the result and want the tuned positi...

Page 269: ...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 pos...

Page 270: ...or Commit Selection and Commit Entire Program Action The robtargets p10 and p30 are added to Selected Targets and tuned once 1 p10 is removed from Selected Targets 2 p30 is tuned again 3 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...

Page 271: ...ected 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 tap...

Page 272: ...e 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 ...

Page 273: ...Offs 3 You can use the filter to narrow down the available data You can also change data type of the available data Tap to select each expression EXP and then tap any of the desired available data or functions 4 You can also tap Edit to access more functions Tap All to open the soft key board and edit all expressions at the same time or tap Only Selected to edit one at a time with the soft keyboar...

Page 274: ... move a robot automatically to a programmed position Information Action On the ABB menu tap Jogging 1 Make sure the correct mechanical unit is selected and then tap Go To 2 If you have many pro grammed positions you can use a filter to narrow down the visible positions See section Filtering data on page 93 Tap to select a programmed position 3 Press and hold the three position enabling device and ...

Page 275: ...d Outputs The list of Most Common I O signals is displayed en0400000770 1 Tap View to change the selection of signals in the list 2 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 275 3HAC050941 0...

Page 276: ... Simulation to remove the simulation from the signal 4 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 accord ingly For a digital signal tap 0 or 1 to change the value of a signal 5 For analog signals and groups tap on 123 to change the signal value The soft nu meric keyboard is displ...

Page 277: ...ed I O device Signals Displays the input and output bit values of the selected device Actions Bit Values Displays the MAC ID of the selected device Note Actions Identify option is available only for the network type EtherNet IP Actions Identify Allows you to configure the selected local I O device Note Actions Configure option is available only for the network type EtherNet IP Actions Configure Co...

Page 278: ...window is displayed It displays the available I O devices Tap View I O Devices 2 Note The Firmware upgrade option is available only for the net work type EtherNet IP Select the EtherNet IP I O device 3 The Device Firmware window is displayed with the details of the firmware xx1800000120 Tap Actions Firmware 4 The firmware for the selected EtherNet IP I O device is upgraded Tap Upgrade 5 278 Operat...

Page 279: ...guring Most Common I O on page 114 1 In the View menu tap Groups 2 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 3 Operating manual IRC5 with FlexPendant 279 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 7 Handling inputs and outputs I O 7 3 Viewing signal group ...

Page 280: ...chain 1 AUTO1 From panel board to main computer 1 Auto selected Op mode selector chain 2 AUTO2 From panel board to main computer 1 MAN selected Op mode selector chain 1 MAN1 From panel board to main computer 1 Man full speed selected Op mode selector chain 1 MANFS1 From panel board to main computer 1 MAN selected Op mode selector chain 2 MAN2 From panel board to main computer 1 Man full speed sele...

Page 281: ...el board to main computer 1 Error 0 OK Overload panel 24V PANEL24OVLD From panel board to main computer 1 Error 0 OK Overload drive mod ules DRVOVLD From axis computer to main computer 1 Chain 1 closed Read back of chain 1 after limit switches DRV1LIM1 From axis computer to main computer 1 Chain 2 closed Read back of chain 2 after limit switches DRV1LIM2 From axis computer to main computer 1 K1 cl...

Page 282: ...STEN1 From main computer to axis computer 1 1 Close chain 1 Signal to interlocking circuit DRV1CHAIN1 From main computer to axis computer 1 1 Close chain 2 Signal to interlocking circuit DRV1CHAIN2 From main computer to axis computer 1 1 Release brake Signal to brake release coil DRV1BRAKE 282 Operating manual IRC5 with FlexPendant 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 7...

Page 283: ...open the event log Action Tap the status bar The status window is displayed 1 Tap Event Log The event log list is displayed 2 If the log contents do not fit into a single screen it can be scrolled 3 Tap a log entry to view the event message 4 Tap the status bar again to close the log 5 Related information Operating manual RobotStudio Operating manual IRC5 with FlexPendant 283 3HAC050941 001 Revisi...

Page 284: ...w menu tap Common 2 Tap Delete and then Delete all logs A confirmation dialog is displayed 3 Tap Yes to delete or No to keep the log intact 4 Delete log entries of a specific category Action Tap the status bar then the Event Log tab to open the event log 1 On the View menu tap the category of choice 2 Tap Delete and then Delete log A confirmation dialog is displayed 3 Tap Yes to delete or No to ke...

Page 285: ...he 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 1 Tap Save all logs as The file dialog is displayed 2 If you want to save the log in a different folder locate and open the folder 3 In the File name box type a name...

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Page 287: ...ion Tap the ABB menu and then tap Backup and Restore 1 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 2 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 star...

Page 288: ...d backup path the correct one 6 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 Copyright 2018 ABB All rights ...

Page 289: ...cal 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 m...

Page 290: ... 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 Copyright 2018 ABB All rights reserved 9 Backup and restore 9 2 Important when performing backups Continued ...

Page 291: ...rectory 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 1 Tap Restore System 2 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 Back...

Page 292: ...in 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 Copyright 2018 ABB All right...

Page 293: ...he 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 293 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved 9 Backup and restore 9 3 Restore the system Continued ...

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Page 295: ...vice technician Not calibrated You must update the revolution counters Rev counter update needed How to update the revolution counters is de scribed in the product manual for the robot No calibration is needed Calibrated DANGER Do not attempt to perform the fine calibration procedure without the proper training and tools Doing so may result in incorrect positioning that may cause injuries and prop...

Page 296: ...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 1 All mechanical units connected to the system are shown along with their calibration status Tap the mechan...

Page 297: ... 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 5 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn may cause damage or injury Check the calibration position very carefully after e...

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Page 299: ...ate systems default settings 123 overview 123 Quickset 82 selecting 82 138 cursor about 167 D danger levels 32 data instance 61 169 data types creating new 169 editing 171 menu 61 viewing 168 date and time 112 default paths setting 100 displacements about 272 work object 193 display 44 E elongator points define 183 emergency stop button 18 44 FlexPendant 38 emergency stops recovering 22 enabling d...

Page 300: ...ded 110 linear mode default settings 123 linear motion mode 129 LoadIdentify 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 about 29 208 limitations 29 208 switching to 261 mechanical unit quickset 79 selecting 79 132 mechanical units activate automatical...

Page 301: ...ystems 82 motion mode 80 run mode 85 speed mode 87 step mode 86 tasks 88 tools 81 work objects 81 quickset menu 41 R RAPID 148 redo instructions 162 reorient mode default settings 123 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 ...

Page 302: ...P 177 working area variations 183 tool coordinates default settings 123 selecting 138 tool frame defining 180 methods 180 reorientation test 183 tool orientation 183 setting 136 tool orientation definition 136 tools aligning 145 creating 177 deleting 188 editing declarations 187 editing definitions 185 editing tool data 184 identifying loads 224 make stationary 189 Quickset 81 selecting 81 135 set...

Page 303: ...selecting 138 write access granting 97 message 91 rejecting 97 Z zooming 92 Operating manual IRC5 with FlexPendant 303 3HAC050941 001 Revision G Copyright 2018 ABB All rights reserved Index ...

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Page 306: ...y Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC050941 001 Rev G en Copyright 2018 ABB All rights reserved Specifications subject to change without notice ...

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