Operating Manual - IRC5 With FlexPendant

Operating manualIRC5 with FlexPendant

Trace back information:Workspace R14-1 version a5Checked in 2014-04-07Skribenta version 4.0.378

Operating manualIRC5 with FlexPendantRobotWare 5.61Document ID: 3HAC16590-1Revision: W Copyright 2004-2014 ABB. All rights reserved.

The information in this manual is subject to change without notice and should notbe construed as a commitment by ABB. ABB assumes no responsibility for any errorsthat may appear in this manual.Except as may be expressly stated anywhere in this manual, nothing herein shall beconstrued as any kind of guarantee or warranty by ABB for losses, damages topersons or property, fitness for a specific purpose or the like.In no event shall ABB be liable for incidental or consequential damages arising fromuse of this manual and products described herein.This manual and parts thereof must not be reproduced or copied without ABB'swritten permission.Additional copies of this manual may be obtained from ABB.The original language for this publication is English. Any other languages that aresupplied have been translated from English. Copyright 2004-2014 ABB. All rights reserved.ABB ABRobotics ProductsSe-721 68 VästeråsSweden

Table of contentsTable of contentsOverview of this manual . 11Product documentation, IRC5 . 393942434445464647485051531.41.523About this chapter .Applicable safety standards .Safety terminology .1.3.1 Safety signals in the manual .1.3.2 Safety symbols on manipulator labels .1.3.3 DANGER .1.3.3.1 DANGER - Make sure that the main power has been switched off! .1.3.3.2 DANGER - Moving manipulators are potentially lethal! .1.3.3.3 DANGER - Robot without axes' holding brakes are potentially lethal! .1.3.4 WARNING .1.3.4.1 WARNING - The unit is sensitive to ESD! .1.3.5 What is an emergency stop? .1.3.6 What is a safety stop? .1.3.7 What is safeguarding? .1.3.8 Safe use of the FlexPendant .How to deal with an emergency .1.4.1 Stop the system .1.4.2 Release the robot holding brakes .1.4.3 Extinguishing fires .1.4.4 Recover from emergency stops .1.4.5 Return to the programmed path .Working in a safe manner .1.5.1 Overview .1.5.2 For your own safety .1.5.3 Handling of FlexPendant .1.5.4 Safety tools .1.5.5 Safety in manual mode .1.5.6 Safety in automatic mode .Welcome to FlexPendant552.12.22.32.42.52.6555663646567About this chapter .What is a FlexPendant? .What is an IRC5 controller? .What is RobotStudio? .When to use the FlexPendant and RobotStudio .Buttons and ports on the controller .Get t this chapter .Connections .3.2.1 Connecting a FlexPendant .3.2.2 Disconnecting a FlexPendant .3.2.3 Set up the network connection .Action scenarios .3.3.1 About action scenarios .3.3.2 System start .3.3.3 Jogging .3.3.4 Using RAPID programs .3.3.5 Working with inputs and outputs .3.3.6 Backup and restore .3.3.7 Running in production .3.3.8 Granting access for RobotStudio .3HAC16590-1 Revision: W5 Copyright 2004-2014 ABB. All rights reserved.

Table of contents3.3.9 Upgrading .3.3.10 Installing software options .3.3.11 Shutting down .4Navigating and handling FlexPendant4.14.24.34.44.54.64.7585868789About this chapter .Overview, personalizing the FlexPendant .The ABB menu .4.3.1 HotEdit menu .4.3.2 FlexPendant Explorer .4.3.3 Inputs and Outputs, I/O .4.3.4 Jogging .4.3.5 Production Window .4.3.6 Program Data .4.3.7 Program Editor .4.3.8 Backup and Restore .4.3.9 Calibration .4.3.10 Control Panel .4.3.11 Event Log .4.3.12 System Info .4.3.13 Restart .4.3.14 Log Off .Operator window .Status bar .Quickset .4.6.1 The Quickset menu .4.6.2 Quickset menu, Mechanical unit .4.6.3 Quickset menu, Increment .4.6.4 Quickset menu, Run Mode .4.6.5 Quickset menu, Step Mode .4.6.6 Quickset menu, Speed .4.6.7 Quickset menu, Tasks .Basic procedures .4.7.1 Using the soft keyboard .4.7.2 Messages on the FlexPendant .4.7.3 Scrolling and zooming .4.7.4 Filtering data .4.7.5 Process applications .4.7.6 Logging on and off 50151152153155157Introduction to jogging .Joystick directions .Coordinate systems for jogging .Restrictions to jogging .Coordinated jogging .Basic settings for jogging .5.6.1 Selecting mechanical unit for jogging .5.6.2 Selecting motion mode .5.6.3 Selecting tool, work object, and payload .5.6.4 Setting the tool orientation .5.6.5 Jog axis by axis .5.6.6 Selecting coordinate system .5.6.7 Locking the joystick in specific directions .5.6.8 Incremental movement for precise positioning .5.6.9 Reading the exact position .63HAC16590-1 Revision: W Copyright 2004-2014 ABB. All rights reserved.

Table of contents6Programming and 6237237238240241242243246246250251252253Before you start programming .Programming concept .6.2.1 The structure of a RAPID application .6.2.2 About the Program and Motion Pointers .6.3 Data types .6.3.1 Viewing data in specific tasks, modules, or routines .6.3.2 Creating new data instance .6.3.3 Editing data instances .6.4 Tools .6.4.1 Creating a tool .6.4.2 Defining the tool frame .6.4.3 Editing the tool data .6.4.4 Editing the tool declaration .6.4.5 Deleting a tool .6.4.6 Setup for stationary tools .6.5 Work objects .6.5.1 Creating a work object .6.5.2 Defining the work object coordinate system .6.5.3 Editing the work object data .6.5.4 Editing the work object declaration .6.5.5 Deleting a work object .6.6 Payloads .6.6.1 Creating a payload .6.6.2 Editing the payload data .6.6.3 Editing the payload declaration .6.6.4 Deleting a payload .6.7 Programming .6.7.1 Handling of programs .6.7.2 Handling of modules .6.7.3 Handling of routines .6.7.4 Handling of instructions .6.7.5 Example: Add movement instructions .6.8 Advanced programming .6.8.1 Mirroring a program, module, or routine .6.8.2 Modifying and tuning positions .6.8.3 Modifying positions in the Program Editor or Production Window .6.8.4 Tuning positions with HotEdit .6.8.5 Working with displacements and offsets .6.8.6 Moving the robot to a programmed position .6.8.7 Aligning tools .6.8.8 Editing instruction expressions and declarations .6.8.9 Hiding declarations in program code .6.8.10 Deleting programs from memory .6.8.11 Deleting programs from hard disk .6.8.12 Activating mechanical units .6.9 Testing .6.9.1 About the automatic mode .6.9.2 About the manual mode .6.9.3 Using the hold-to-run function .6.9.4 Running the program from a specific instruction .6.9.5 Running a specific routine .6.9.6 Stepping instruction by instruction .6.10 Service routines .6.10.1 Running a service routine .6.10.2 Battery shutdown service routine .6.10.3 Calibration Pendulum, CalPendulum service routine .6.10.4 Service Information System, ServiceInfo service routine .6.10.5 LoadIdentify, load identification service routine .3HAC16590-1 Revision: W7 Copyright 2004-2014 ABB. All rights reserved.

Table of contents7Running in 772792812827.27.38Handling inputs and outputs, I/O2838.12832832842852862882892912918.29Basic procedures .7.1.1 Starting programs .7.1.2 Stopping programs .7.1.3 Using multitasking programs .7.1.4 Using motion supervision and non motion execution .7.1.5 Using the hot plug option .Trouble shooting and error recovery .7.2.1 General procedure when trouble shooting .7.2.2 Returning the robot to the path .7.2.3 Running RAPID program with uncalibrated mechanical unit .Operating modes .7.3.1 Present operating mode .7.3.2 Switching from manual to automatic mode .7.3.3 Switching from automatic to manual mode .7.3.4 Switching to manual full speed mode .Basic procedures .8.1.1 Viewing signal lists .8.1.2 Simulating and changing signal values .8.1.3 Viewing signal group .8.1.4 Configuring I/O .8.1.5 Deactivating and activating I/O units .8.1.6 Alias I/O signals .Safety signals .8.2.1 Safety I/O signals .Handling the event log2959.1295295296297Basic procedures .9.1.1 Accessing the event log .9.1.2 Deleting log entries .9.1.3 Saving log entries .10 Systems29910.1 What is a system? .10.2 Memory and file handling .10.2.1 What is “the memory”? .10.2.2 The structure of the main computer RAM memory contents .10.2.3 File handling .10.3 Restart procedures .10.3.1 Restart overview .10.3.2 Using the Boot Application .10.3.3 Restart and use the current system (warm start) .10.3.4 Restart and select another system (X-start) .10.3.5 Restart and delete the current system (C-start) .10.3.6 Restart and delete programs and modules (P-start) .10.3.7 Restart and return to default settings (I-start) .10.3.8 Restart from previously stored system (B-start) .10.3.9 Reflashing firmware and FlexPendant .10.4 Installed Systems .10.4.1 Managing Installed Systems .10.5 Back up and restore systems .10.5.1 What is saved on backup? .10.5.2 Back up the system .10.5.3 Restore the system .10.5.4 Important when performing backups! 3173193193213233253HAC16590-1 Revision: W Copyright 2004-2014 ABB. All rights reserved.

Table of contents10.6 Diagnostic files .10.6.1 Creating a diagnostic file .10.7 System configuration .10.7.1 Configuring system parameters .11 Calibrating33111.1 Basic procedures .11.1.1 How to check if the robot needs calibration .11.1.2 Updating revolution counters .11.1.3 Loading calibration data using the FlexPendant .11.1.4 Editing motor calibration offset .11.1.5 Fine calibration procedure on FlexPendant .11.1.6 Serial measurement board memory .11.1.7 4 points XZ calibration .12 Changing FlexPendant settings12.1 System settings .12.1.1 Setting default paths .12.1.2 Defining a view to be shown at operating mode change .12.1.3 Changing the background image .12.1.4 Defining visibility level for UAS protected functions .12.1.5 Defining an additional test view .12.1.6 Defining position programming rule .12.1.7 Defining which tasks should be selectable in the tasks panel .12.2 Basic settings .12.2.1 Changing brightness and contrast .12.2.2 Adapting the FlexPendant for left-handed users .12.2.3 Changing date and time .12.2.4 Configuring Most Common I/O .12.2.5 Changing language .12.2.6 Changing programmable keys .12.2.7 Calibrating the touch screen .13 Descriptions of terms and 26326327327About this chapter .What is the robot system? .What are mechanical units, manipulators and positioners? .What is a tool? .What is the tool center point? .What is a work object? .What is a coordinate system? .What is a RAPID application? .What is mirroring? .What is a data array? 693703763773833853HAC16590-1 Revision: W9 Copyright 2004-2014 ABB. All rights reserved.

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Overview of this manualOverview of this manualAbout this manualThis manual contains instructions for daily operation of IRC5 based robot systemsusing a FlexPendant.UsageThis manual should be used during operation.Who should read this manual?This manual is intended for: operators product technicians service technicians robot programmersHow to read the operating manualThe operating manual is structured in the following chapters.ChapterTitleContent1SafetySafety instructions and warnings.2Welcome to FlexPendant Descriptions of the FlexPendant and the controller.3Get startedDescriptions of connections and step-by-step instructions to the most common tasks4Navigating and handlingthe FlexPendantDescriptions of the FlexPendant’s user interfaceand basic procedures.5JoggingProcedures for jogging.6Programming and testing Procedures for programming and testing, includingde

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