ABB IRC5 Operations

Reference Manual

Valentine Robotics School for Continuing Education

36625 Metro Ct. Sterling Heights, MI 48312 (586)979-9900 http://www.valentinerobotics.com

ABB IRC5 Operations Reference

Table of Contents

Table of Contents

Section 1Terminology & Safety ...........................................................................................1 Section 2Control Panel & FlexPendant ...............................................................................5 Section 3Power-Up & Error Recovery ...............................................................................11 Section 4Jogging & Coordinate Systems .........................................................................15 Section 5Executing Programs ...........................................................................................23 Section 6Inputs & Outputs .................................................................................................27

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ABB IRC5 Operations Reference

Section 1 Terminology & Safety

Terminology

FlexPendant

The FlexPendant is the hand-held programming unit attached to the controller. It has a color touch screen, symbolic buttons, a joystick, an emergency stop button, and an enabling device. The enabling device is often referred to as the dead mans handle. When pressed to the center position in manual mode, this three-position button allows power to the motors, enabling robot motion. In the event the operator drops the FlexPendant, releases the button, is crushed or electrocuted, or has depressed the button in too far, the robot will stop immediately. The safety chain is the robots safety circuit, which consists of a two-channel 24 volt DC and 0 volt DC circuit. Any time either circuit is incomplete, the robot will stop immediately. The safety chain consists of various circuit sections such as auto stops, emergency stops, general stops, limit switches, the enabling device, etc. Jogging is a way to operate the robot manually using the joystick. This is only possible in manual mode. Cycling is a way to execute an entire robot routine either continuously or through one single cycle. This can be done in either auto or manual mode by pressing the button on the FlexPendant. Stepping is a way to execute a robot routine one line at a time. This can be done in either auto or manual mode by pressing the buttons on the FlexPendant. A task is a folder that contains information such as programs and data. A module is a file that stores routines and data. There are two types of modules: program modules and system modules. A routine is an actual program that the robot executes when cycling. An average program cycle will execute multiple routines. The cursor is designated by a _highlighted_ line in the routine. The cursor is used to view and edit program instructions or change operation parameters. The PP (program pointer) points to the next line of the program that will be executed. Once a line has executed, the PP will automatically move to the next line of the routine. The motion pointer points to the last motion instruction that was executed. Unless the robot is manually moved via jogging or the brake release buttons, the motion pointer indicates the current position of the robot. Data is the stored information (usually numbers) that is used by the robots programs. There are many data types, which are structured combinations of numbers. Arguments are the parameters of an instruction. Typically, each argument references a number or a piece of data. Some instructions use several arguments.

Enabling Device

Safety Chain

Jogging Cycling

Stepping Task Module Routine Cursor PP Motion Pointer

Data Argument

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Axes Motion

Axes motion is used to move a robots individual motors in a positive or negative direction. When jogging the robot in this mode, the robots motion is arcing. Axes motion, often referred to as joint motion, is used for rough positioning, calibrating the robot and programming around singularity. Cartesian motion uses various coordinate systems to move the robot along (Linear) or around (Reorient) X Y or Z axes. The manipulator is the actual mechanical unit, or robot. A joint (or axis) is a point of movement on the robot, usually connected to a motor. The face plate is located on the robot at the end of axis 6. It is used to bolt the end effector onto the robot. The center of the face plate is referred to as the default TCP (tool0). The end effector is the tooling bolted to the end of the robot arm. Some examples include grippers, glue or sealant guns, arc welding torches, stud weld or spot-weld guns, plasma or HVOF guns, laser or water jet cutters, etc. Once an end effector is added to the robot arm, the TCP (tool center point) is used to tell the robot where this additional equipment is located. The TCP is an XYZ offset measured from the face plate of the robot. A hard stop is a mechanical device that prevents a robot axis from moving beyond a given point. A soft stop is a software setting that prevents a robot axis from moving beyond a given point. 0 = Off = False = Reset = 0 VDC or 0 VAC 1 = On = True = Set = 24 VDC or 120 VAC

Cartesian Motion Manipulator Joint (or Axis) Face Plate

End Effector

TCP

Hard Stop Soft Stop 0 1

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Safety
Whenever working around any type of automated equipment, you must follow your plants safety guidelines and proper lockout/tagout procedures. Your individual safety is dependent on the decisions you make while working with automated equipment. Do not take your life and safety for granted. Industrial equipment is very powerful and fast. Do not enter any work cell unless you are fully aware the robots and other machinery are in a safe state.

Robot Considerations
If you must work in a robotic cell, you must place the robot in manual reduced speed mode (< 250 mm/sec) from the operators panel before entering the cell. DO NOT stand within the work envelope of any robot which you personally do not have control of through the use of the FlexPendant. DO NOT trust anyone but yourself when it comes to your personal safety. Personally check to make sure all devices are locked out. DO NOT place yourself between the robot and any fixed object in the cell; this is known as a pinch point. ALWAYS visually inspect the cell that you will be working in. Plan out escape paths ahead of time, and be aware of anything that could be a pinch point or a trip hazard. DO NOT manually jog or cycle any robot unless you are visually monitoring the system. ALWAYS cycle the robot in step mode at a reduced rate of speed after making program changes. DO NOT test cycle the robot from within the cell. ALWAYS E-STOP the robot whenever there is a danger to people or equipment. DO NOT jumper out or change any program signals that may allow safety circuits to be compromised.

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Electrical
ALWAYS lockout electrical equipment before doing any electrical work. ALWAYS use an electrical measuring device (voltmeter, etc.) to verify that power is disconnected. ALWAYS check three-phase voltages both phase-to-phase and phase-to-ground. ALWAYS test your voltmeter on a known live source to verify that it is working correctly. ALWAYS follow your plants safety guidelines and proper lockout procedures. DO NOT trust any one but yourself when it comes to your personal safety. Personally check to make sure all devices are locked out.

Pneumatic/Hydraulic
Lockout and depressurize all pneumatic and hydraulic equipment prior to working in the cell. Working on any system without first depressurizing the equipment can result in an injection hazard.

Chemicals
Treat all chemicals, adhesives, sealant, and urethane as hazardous chemicals unless you know otherwise. Remember, all chemicals can be absorbed through the skin, lungs, and mucous membranes. Immediately wash off any chemicals you come in contact with.

Please be safe whenever working around any automated equipment!

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ABB IRC5 Operations Reference

Section 2 Control Panel & FlexPendant

Robot Control Panel

The IRC5 controller can be configured in various ways. The control module and drive module can be integrated into the same cabinet or they can be separated into smaller, stackable cabinets. Furthermore, additional drive module cabinets can be added for control of multiple robots or external axes from one controller. This manual will focus on the most common version, the integrated cabinet (see Figure 2A). The control panel (see Figure 2B), however, is basically the same on all of the cabinet combinations.

Figure 2A

Figure 2B

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Robot Operation Mode Switch

The operating mode of the robot is determined by the position of the switch (keyswitch or selector switch) on the operators panel.

Manual Reduced Speed The operation mode switch must be placed in Manual Reduced Speed Mode (less than 250 mm/sec) whenever entering the robot work cell. This is the safest mode to use whenever jogging, programming, or test cycling the robot. Overall motion will be reduced to 10% of maximum speed when working in this mode. Do not enter the work cell when the robot is in Manual 100% or Automatic Mode. Serious injury may occur.

Manual Mode 100%

(Not on all robots)

This switch position is used to test cycle at actual production speeds. When using this mode, you must not be in the work cell. An additional enabling button located on the FlexPendant is required for operation. Both FlexPendant enabling devices must be pressed in order to test cycle a robot. Before cycling the robot in this mode, verify the following: There must be no one in the work cell. The correct routine must be selected, and the program pointer must be in the correct location, or a crash will occur. The gates must be closed to prevent anyone from entering the work cell.

Once the operation mode switch is turned to Manual Full Speed Mode, verify the change of mode by tapping OK on the FlexPendant screen.

Automatic Mode This robot mode switch position is used for running production only. Before placing the robot in Automatic Mode, verify the following: The program pointer ( o o ) must be in the proper position: Line 1 of the Main program if restarting the cycle The last line executed if continuing the cycle

The robot must be at home or have an unobstructed path to the home position. There must be no one in the work cell. All gate plugs, safety mats, and light screens must be restored and reset.

Once the operation mode switch is turned to Automatic Mode, verify the change of mode by tapping OK on the FlexPendant screen.

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FlexPendant
The IRC5 FlexPendant is the device used to interface to the robot controller. It has an emergency stop button, an enabling device, a joystick, hardware buttons, and a color touch screen.

FlexPendant Screen
The FlexPendant has many screens in its software, but there are some key areas of the screen to get familiar with first. They are shown below.

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ABB Menu
The ABB Menu is a quick way to navigate to nearly any screen on the FlexPendant. The most commonly used screens (Inputs and Outputs, Jogging, Production Window, etc.) are covered later in this manual. The various menu options can be broken into three basic categories: Operation, Editing, and Service.

Operation Menu Options

Editing Menu Options

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Service Menu Options

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ABB IRC5 Operations Reference

Section 3 Power-Up & Error Recovery

Controller Power-Up
Safety Preparation: Make sure that no one is inside the work cell. Verify that the controller mode selector switch is in manual mode (reduced speed). Make sure the robot is powered up according to the plant-specified start-up sequence.

Tip for Power-Up The controller should be powered down for at least 30 seconds before powering up (to avoid corrupting the memory). On a multi-cabinet robot system, the drive cabinet disconnect(s) should be turned on before turning on the control cabinet disconnect. Make sure the FlexPendant is connected before powering up. Once powered up, the FlexPendant should not be connected or disconnected.

Once the controller has fully powered up, a Welcome screen appears. This screen shows the controllers ABB menu, QuickSet menu, Status Bar and the Operator Window icon. If there are complications during power-up, a message appears in the Status Bar.

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Recovering From Errors

Whenever an event or error occurs, the operating system generates one or more messages in the Event Log, which can be viewed by tapping on the Status Bar. Note When troubleshooting error messages, start at the top of the Event Log and work down through the list to determine the root cause error. The most recent messages are displayed at the top of the list, but they are often triggered by a previous error a few lines down.

There are three basic types of messages: Error Message Indicates some type of fault in the robot system. These messages must be acknowledged. Warning Message Indicates a problem in the system. These messages do not have to be acknowledged, although they do typically require attention. Informational Message Indicates a change of state or an error that doesnt require acknowledgement. These messages are both informational and helpful.

If an error message requires attention, it appears in the Status Bar. The message can be viewed by tapping on the Status Bar. Error messages and warning messages often give both a description and a suggested action for recovery. Some messages require acknowledgement, which is done by tapping Acknowledge (while the message is displayed). Emergency stop errors also require that the Motors On button (also called the panel button) be pressed to reset the E-stop condition.

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Informational messages typically give a detailed description of the condition as well as the consequences, or implications of the condition. Occasionally, probable causes of the condition are included, which are listed in order of probability. Additionally, some informational messages can give recommended actions to help resolve the condition.

Tip Additional pop-up windows may ask the operator questions, requiring a decision. Because there is no escape key on the FlexPendant, it is imperative that these questions are read before they are answered. These windows contain limited choices and often have an option to Cancel. If for any reason you are unsure of the action you are taking, use Cancel to back out of the question. A simple mistake could cause accident or injury.

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ABB IRC5 Operations Reference

Section 4 Jogging & Coordinate Systems

Jogging Screen
The Jogging screen is used as an informational display to aid the operator when jogging the robot. Use of this screen is not required, although it is very helpful when jogging. The following pages detail the various motion modes and coordinate systems. Listed below are the various features of the Jogging screen and their meanings. Tip Any Jogging screen feature with a after it can be modified by tapping on the current selection.

Figure 4A

Mechanical unit: Refers to the mechanical unit currently selected for jogging. ROB_1 represents the first robot. Another name such as ROB_2 would represent a second robot. Other names such as TT1 or RAIL1 may represent auxiliary axes (turntable, rail, etc.). Absolute accuracy: Optional calibration feature used to keep the robot extremely accurate (within 0.5mm). Motion mode: Displays the current motion type selected for jogging (Axis 1-3 shown above). The user can select from Axis 1-3, Axis 4-6, Linear, and Reorient, which are discussed later in this section. Coordinate system: Refers to the current coordinate system selected for jogging when in linear or reorient mode (World shown above). The user can select from World, Base, Tool, and Wobj, which are discussed later in this section. Tool: Lists the currently selected tool center point (tGrip1 shown above). The user can select from other predefined tool center points (TCPs) by tapping on the current selection. Work object: Lists the currently selected work object frame (wobj0 shown above). The user can select from other predefined work objects by tapping on the current selection. This feature is not used in all applications. Payload: Displays the current payload setting (load0 shown above). This feature is often used in material handling applications that involves very heavy parts. Joystick lock: Allows the user to lock out undesired joystick directions. Locked joystick directions are displayed in the Jogging screen with a lock icon. Increment: Allows the user to jog the robot slower by selecting between Small, Medium, Large, or User increments.

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Jogging Modes
There are four modes available for jogging: Axis 1-3, Axis 4-6, Linear, and Reorient. These modes can be selected either by tapping the Motion mode item in the Jogging screen, or by using the QuickSet menu icon at the bottomright of the screen.

Motion Mode Selection

When the Motion mode item (see Figure 4A) is tapped, the screen to the right appears. A jogging mode can be selected by tapping its icon, and then by tapping OK at the bottom of the screen. Note This method can only be done from the Jogging screen.

QuickSet Menu Selection

QuickSet is a menu that can be used to quickly change jogging settings from any screen. When the QuickSet icon is tapped, and then the icon is tapped, the QuickSet menu expands as shown in Figure 4B. Any item can be tapped to modify current settings. When < < Show Details is tapped (see Figure 4B), the menu expands further as shown in Figure 4C.

Figure 4B

Tapping these options allow them to be changed as well. Once the options are set as desired, the menu can be closed by tapping the QuickSet button.

Figure 4C

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Axis 1-3 Mode

Jogging in this mode will move axis 1, 2, and 3.

Axis 4-6 Mode

Jogging in this mode will move axis 4, 5, and 6.

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Linear Mode
Jogging in this mode will move the robots tool center point along the selected Cartesian (X Y Z) coordinate system. The various coordinate systems are discussed later in this section.

Reorient Mode
Jogging in this mode will rotate the robots end effector around its tool center point with directions of rotation based on the selected Cartesian (X Y Z) coordinate system. The various coordinate systems are discussed later in this section.

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Coordinate Systems
There are four basic coordinate systems used for jogging: World, Base, Tool, and Wobj. They can be selected either by tapping the Coordinate system item in the Jogging screen (see Figure 4A) or by using the QuickSet menu. Although some coordinate systems are more versatile than others, each has its own purpose in making robot jogging an easier task. All of the coordinate systems have X Y Z directions defined by the ABB right hand rule. The coordinate systems are covered in detail below.

Base Coordinates
The Base coordinate system uses an X Y Z frame originating from the center of the base of the robot. The directions of X Y Z reference the back of the base (cables plug-ins) as the X direction and the top of the robot as the +Z direction. Note If the robot is hung upside down, the Base coordinate system will also be upside down. This coordinate system is useful when machines and fixtures are mounted square to the base of the robot. Otherwise, jogging can be made easier by using another coordinate system.

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World Coordinates
The World coordinate system is an X Y Z frame originating from a point taught inside the robots workspace. If the World frame is left untaught (at default values), it is identical to the Base coordinate system. This coordinate system is useful in applications where a robot is hung upside down or mounted to a wall. Also, in multiple robot systems where two or more robots have differing orientations, the World coordinate system can be used to create a common set of X Y Z directions.

Tool Coordinates
The Tool coordinate system uses an X Y Z frame originating from the robots tool center point (TCP). Because the robot can have multiple TCPs, it can also have multiple Tool coordinate frames. This coordinate system is extremely useful in applications where the parts or fixtures are at angles to the base of the robot. This is because, as the end effector changes orientation, so does the Tool coordinate frame.

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Wobj Coordinates
The Work Object coordinate system is used to define various work locations and orientations around the robot. A robot can have many Work Objects in its system to correspond to its many work areas. Each Work Object consists of two frames: a User frame and an Object frame. The two frames can share the same location, or they can have different origins. Caution! Whenever modifying programmed positions on a robot that uses Work Objects, it is extremely important that the correct Work Object is selected in the Jogging screen, or a crash or error may occur!

User Frame The User Frame is used to define the location/orientation of a work area, such as a table. The User frame is part of the Work Object, and its location is relative to the World coordinate frame. Object Frame The Object frame is used to define the location of a part or fixture within a work area. The Object frame is part of the Work Object, and its location/orientation is relative to the User frame. For example, a part location on a fixture could be represented by an Object frame relative to a User frame. Any jogging or point modifying done with a given Work Object will be relative to the Object frame within that Work Object.

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ABB IRC5 Operations Reference

Section 5 Executing Programs

Executing Programs
Program (or routine) execution can be done in either manual or automatic mode. A routine may be executed in its entirety or one line at a time. When in manual mode, either the Production Window or the Program Editor screen must be viewed while executing a routine. Both screens display the currently selected task, module, and routine (T_ROB1/MainModule/rHome in the example below) at the top of the screen. The Production Window and Program Editor screens are both covered in this section.

Program Execution Buttons

The FlexPendant has four program execution buttons. They are as follows:

Production Window
The Production Window is used to execute routines without editing capabilities. This is to avoid accidental program changes. One limitation of the Production Window is that individual routines cannot be selected. The only routine that can be selected for execution is Main. Again, this is to avoid accidentally executing a routine out of sequence.

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Program Editor
The Program Editor is used to select, execute, and edit routines. CAUTION The editing features of this screen should only be used by authorized, trained personnel!

One advantage of this screen is the ability to select any routine for execution. This is done using the Debug menu shown in figure 5A. Tip When selecting a routine, there are a few things to consider: If starting the robots cycle over to run in auto mode, PP to Main should be selected. If testing an individual routine other than the Main routine, PP to Routine should be selected. If using a routine for one cycle (i.e. rOpenGripper), Call Routine should be selected.
Figure 5A

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QuickSet Menu
QuickSet is a menu that can be used to quickly change program execution settings from any screen. There are three QuickSet submenus that correspond to program execution: Run Mode, Step Mode, and Speed. Run Mode When the QuickSet icon is tapped, and then the menu expands as shown in figure 5B. icon is tapped, the QuickSet

The options can be used to adjust the way a routine executes when the Start Cycle button is pressed. Single Cycle will cause the robot to run the routine once, whereas Continuous will cause the robot to run the routine repeatedly until it is instructed to stop.

Figure 5B

Step Mode When the QuickSet icon is tapped and then the menu expands as shown in figure 5C. icon is tapped, the QuickSet

These options can be used to adjust the way a routine executes when the Step Forward and Step Backward buttons are pressed.

Figure 5C

Speed When the QuickSet icon is tapped and then the menu expands as shown in figure 5D. icon is tapped, the QuickSet

These options can be used to scale the overall speed of robot motion. Note When the mode selector switch is turned to manual reduced speed mode, the robots overall speed is scaled to about 10% of the speed setting in the QuickSet menu. For example, a QuickSet speed setting of 80% would actually result in a manual reduced speed of about 8%.

Figure 5D

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Program Flow
Most robots are programmed to do many different things. Even a simple application will sometimes have variations that determine how the robot performs its job. These variations in the robots work are typically broken up into subroutines. When executing a program, jumping from one subroutine to another can become confusing. The use of subroutines is illustrated below in a simple material handling program. It shows how a program will flow when using subroutines.

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ABB IRC5 Operations Reference

Section 6 Inputs & Outputs

Inputs and Outputs

The Inputs and Outputs (I/O) Screen is a useful tool for verifying conditions and diagnosing problems on the robot. The I/O Screen is used to monitor inputs and toggle outputs from the teach pendant. Each signals Name, Value, and Type is listed on this screen. The values of outputs (DO, GO, AO) can be modified, although the values of inputs (DI, GI, AI) can only be monitored. There are three basic types of signals: digital, group, and analog.

Digital I/O
Digital signals can have a value of either 0 (off) or 1 (on), and are used for anything from gripper valves and switches to PLC and weld controller communications. Examples of DI signals are diPartPres, dniZone2ClrToEntr, diWeldComplete, etc. Examples of DO signals are doOpenGrip, dnoRbtAtHome, etc.

Group I/O
Group signals consist of 2 to 16 digital signals grouped together in order to send integer numbers between the robot controller and other controllers, such as PLCs. A group signal can have an integer value from 0 to 65,535, depending on the number of digital signals that are grouped together, as shown below. Example: Shown to the right is a group output consisting of five digital outputs (do4, do5, do6, do7, and do8). Each output has a binary select value (1, 2, 4, 8, 16) in the group output. Each digital output that is on will insert its binary select value into the group output. The range of possible values for this group output is 0 - 31, because the binary select values of all five digital outputs add up to 31. If more digital signals were used, the range of numbers would be greater. Examples of GI signals are giPartStyle, giWeldFault, etc. Examples of GO signals are goStyleAckNum, goWeldID, etc. Digital Output do4 do5 do6 do7 do8 Binary Select Value 1 2 4 8 16 Output Status 1 0 1 0 1 Total +1 +0 +4 +0 + 16 21

Analog I/O
Analog signals are typically used with devices such as weld controllers, proportional valves, variable frequency drives, etc.-- anything that works with a variable signal rather than a simple on or off. Analog signals can have range of values, depending on how they are set up. Examples of AI signals are aiWirefeed, aiTankTemp, etc. Examples of AO signals are aoTTRPM, aoWirefeed, etc.

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View Menu
The View menu can be used to narrow down the number of signals displayed by breaking the signals up into categories, as shown below. I/O Buses I/O Units All Signals Digital Inputs Digital Outputs Analog Inputs Analog Outputs Groups Input Groups Output Most Common Safety Signals Simulated Signals Displays the status of each of the robots I/O communication buses. Displays the status of each of the robots configured I/O units. Displays all of the robots user signals. Displays all of the robots digital inputs. Displays all of the robots digital outputs. Displays all of the robots analog inputs. Displays all of the robots analog outputs. Displays all of the robots grouped inputs. Displays all of the robots grouped outputs. Displays only the most commonly used I/O signals. This is set up using the I/O menu option in the Control Panel. Displays all of the robots system signals related to the run chain. Displays all of the user signals currently being simulated. Signal simulation is covered below.

Signal Simulation
The Simulate option allows the user to change the software value of a signal. This user-entered value does not actually change the state of the device; it simply fakes out the software. Once a signal is simulated, its Simulated entry is displayed as True. Simulation can be used as a temporary measure to sidestep input signals. For example, if a part present input is not turning on due to a damaged switch, that signal can be simulated. The input on the I/O unit will be off, although the software will read its simulated value. Simulation can also be used to bypass an output signal. For example, if a solenoid valve is short-circuited, turning on its corresponding output will blow a fuse. Simulating the signal will leave the actual output off despite any instructions in the program that turn the signal on. Note A simulated signal does not update to/from its physical device and remains a simulated value until it is unsimulated.

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2007 Valentine Robotics School for Continuing Education

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Other Options
When viewing an I/O unit, tapping the Signals button will display the current states of all of the named signals associated with that I/O unit. This is a quick way to differentiate between hardwired I/O signals and network communication I/O signals (i.e. Profibus, Interbus S, etc.). Also, when viewing an I/O unit, tapping the Bit Values button will display the current states of all of the inputs and outputs associated with that I/O unit. Although the names of the signals are not shown, this is a quick, compact way to view many signals at once.

Suggested I/O Naming Conventions

Shown below is a list of suggested I/O naming conventions.

Signal Type Hardwired Digital I/O Digital I/O via DeviceNet Digital I/O via Profibus Digital I/O via Remote I/O Hardwired Group I/O Group I/O via DeviceNet Group I/O via Profibus Group I/O via Remote I/O Analog I/O

Naming Prefix di do dni dno pbi pbo ri ro gi go gni gno gbi gbo rgi rgo ai ao

Examples diPartPresent doReleaseGrip dniClearToEnter dnoRbtAtHome pbiClearToEnter pboRbtAtHome riClearToEnter roRbtAtHome giToolID goToolRequest gniStyleNum gnoStyleAckNum gbiStyleNum gboStyleAckNum rgiStyleNum rgoStyleAckNum aiWirefeed aoTTRPM

I/O troubleshooting can be made easier by adding a prefix to each signal name. For example, a signal named diFixtureClear appears to be an input that comes from the fixture itself. But, using the naming prefix, dni, dniFixtureClear appears to come from the PLC via DeviceNet. The signals prefix alone can help to determine where to begin troubleshooting.

2007 Valentine Robotics School for Continuing Education

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2007 Valentine Robotics School for Continuing Education

v. 1.00

All rights reserved. No Part of this work covered by the copyright hereon may be reproduced or used in any form or by any meansgraphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems without express written permission of Valentine Robotics, Inc.