Basic Programing S4

ABB Malaysia - 1 Jun 16, 2015
S4CPlus Robot
Basic Programming
Training
Syllabus
ABB Basic Programming Training - 2 Jun 16, 2015
1.1 System Overview
General
Manipulator
Controller
Teach Pendant
Safety
Syllabus (cont 1)
1.2 Basic Operation
Starting the System
Working with Windows
Jogging the Robot Using Joystick
Working on Program
Automatic Mode
Error
I/O Signal
Syllabus (cont 2)
2.1 Robot Coordinate System
Tool Coordinate System
Work Object Coordinate System
Creating TCP
Calibration and Counter Update
Backup & Restore
Syllabus (cont 3)
2.2 Program Structure and Overview
Program
Program Memory
Module
System Module
Routine
Data
Path Programming
Instruction
Expression
Procedure and Functions
Syllabus (cont 4)
3.1 Programming
Basic Instruction
MoveL
MoveJ
3.2 Intermidiate Instruction
MoveC
ProcCall
Move with Offset
WaitTime
Syllabus (cont 5)
3.3 I/O Signal Instruction
Set
Reset
Pulse
3.4 Advance Instruction
Compact IF
IF-THEN
IF-THEN-ELSE
IF-THEN-ELSEIF-THEN-ELSE
WaitDI
WaitUntill
Syllabus (cont 6)
3.4 Advance Instruction
WHILE-DO
FOR
TEST
GOTO
STOP AND EXIT
BREAK
Mathematic Instruction
TP Instruction
Comment
General
Controller
Manipulator
A robot is a combination of two principal

parts: Controller and Manipulator
The Manipulator
Manipulator,
IRB2400
Please observe each axes movement

direction of the manipulator.
The Manipulator
Definition of Robot Axes:
Joints
Degrees of Freedom
Robot Axes:
Axis 1:
Axis 2:
Axis 3:
Base rotates 180
Axis 4:
Axis 5:
Axis 6:
Roll 300
Lower Arm 70
Upper Arm +105 -28
Pitch 120
Roll 300
Teach Pendant and Operator Panel
Teach Pendant
Operator Panel
The teach pendant and operator panel are

used to communicate with the robot.
The Controller
S4C Control System
The controller is consist of 4 principal

parts.
The Controller
KEY SWITCH
Control Description
AUTO (Production Mode)
MANUAL (Teach Mode)
MANUAL 100% (Teach Full Speed)
Control Panel
S4C Controller
Operators Panel
AUTOMATIC MODE (Production Mode)
Used to run for Production.
Jogging robot is not-allow in this mode.
MANUAL REDUCED SPEED MODE (Programming

mode)
Used to do programming, move to robot manually, and
parameter setting
Need to press the enabling device to activate the robots
motors.
Operators Panel
MANUAL FULL SPEED MODE
(Testing mode, Optional)
Used to test run the robot program at full programmed

speed.
Need to press the enabling device and Hold-To-Run to
activate the robots motors.
Control Description
MOTORS ON (an illuminated push-button) is used to start the

motors in AUTO mode. When lit, it indicates that the robot
motors are ON. When the button is flashing the motors are off.
This button is also used to reset Emergency Stop conditions.
Control Panel
S4C Controller
The Controller
Control Description
EMERGENCY STOP
(push-button) immediately
stops robot operation regardless of previous states
and operational mode. No voltage is transmitted
to the motors in the Emergency Stop condition.
Control Panel
S4C Controller
The Controller
Control Description
The HOUR METER is used to keep track of

operational hours that the robot has ran. This
meter is used for maintenance scheduling.
Control Panel
S4C Controller
Teach Pendant
Joystick
Hold-to-Run
LCD Display
Enabling device
Emergency Stop
Teach Pendant
Emergency stop
The robot stops regardless of which state or
mode the system is in immediately the
emergency stop button is pressed.
Enabling device (for safe operation)
Enabling device is a press switch with three positions
The switch must be in the middle in order to activated the

motors in manual mode
All robot movement will immediately stop if the switch is

released or pressed to the bottom
Teach Pendant (cont 2)

Joystick
The joystick is used to jog (move) the robot manually; e.g.

when programming the robot.
Display
Display all information during programming, to change

programs.
Can accommodate 16 lines.
Each line can accommodate 40 characters..
Teach Pendant Keys Overview

Windows Keys (to select a window to work with)
Jogging
Used to jog the robot.
Program
Used to program and test.
Inputs/Outputs
Used to manually operate the input and output signals

connected to the robot.
Misc
Miscellaneous; other windows, i.e. the System Parameters,

Service, Production and File Manager windows.

Navigation Keys (to move the cursor)
List
Press to move the cursor from one part of window

to another.
Previous/Next Page
Press to see the next/previous page.
Up and Down arrows
Press to move the cursor up or down.
Left and Right arrows
Press to move the cursor to the left or right.

Navigation Keys (to move the cursor)
Motion Unit
Press to jog the robot or other mechanical units
Motion Type
Press to select how the robot should be jogged, reorientation

or linear.
Motion Type
Axis by axis movement. 1=axis1-3, 2=axis4-6
Incremental
Incremental Jogging on/off

Other Keys
Stop
Stops program execution.
Contrast
Adjusts the contrasts of the display.
Menu Keys
Press to display menus containing various commands.
Function Keys
Press to select the various commands directly.
Delete
Deletes the data selected on the display.
Enter
Press to input data

Programmable Keys
Functions to be defined by the user.
Safety
Safety Functions
Emergency Stop.
Enabling Device
Safety Stop
Reduced Speed
Interlock
Hold-to-run-control
Starting the System
Before switch the system on, make sure

that no one inside the safeguarded
space around the robot.
Switch the mains switch on. The robot is

then automatically checked.
After the system has been checked and

no errors are located, the welcome
message appears on the display.
Mains Switch
Welcome Screen

Accessing the Inputs/Outputs Window:
1.
Press the Inputs/Outputs window key.
Windows for manual I/O handling

2.
The window for manual I/O is shown on the

display. When a digital output is selected, its
status can be changed using the function keys.
3.
You can move around the windows by pressing keys below:

Movement
Select
One line up
Arrow Up
One line down
Arrow Down
To the first line in the list
Goto top from the Edit menu
To the last line in the list
Goto bottom from the Edit menu
Next Page
Next page
Previous Page
Previous page
Select a specific line in the list Goto from the Edit menu; enter
the desired line number and
press OK
A window with two parts.

4.
Windows are sometimes divided to 2 by a double line.
5.
Select an output, two function keys will be displayed.
6.
Turn On/Off the output by pressing the 0 / 1.
7.
Move to different windows by pressing Window Keys
The four window keys

8.
There are four window keys on the teach pendant.
9.
When you press a window key, the active window will be

hidden under the new window.

Linear Jogging
Robot
1.
Turn the operating mode selector to the

<250mm/s position.
2.
Check that the Robot motion Unit

and Linear motion Unit are selected.
With the Motion unit key, you can choose
between operating the robot or other
external unit connected to controller.
With Motion type key, you can choose

robot to move in:
Linear
a.
Linear movement
b.
Reorientation of particular end effector
c.
Axis-by-axis movement
Linear Jogging
The Robot Coordinate System
When linear type motion is selected, the robot will move as

shown in figure above.

Linear Jogging
The centre of the face plate: TCP 0
The Tool Center Point (TCP) 0, is the point that move

linearly, along the axes of the coordinate system.
The TCP0 is located at the front of the upper arm, in the

centre of the robots face plate.

Linear Jogging
Robot movements with different joystick deflections

3.
Push the enabling device halfway to switch the MOTORS ON.
4.
Jog the robot using the joystick. Standing in front of the robot,
the TCP0 will, depending on how the joystick is moved, move
linearly along the X-, Y- and Z-axes.
The robot can be moved in several directions
simultaneously.
The larger the joystick deflection, the faster robot moves.
Jogging The Robot

Motion Types
Robot
Major Axes 1,2,3
Minor Axes 4,5,6
Linear / Reorientation
Base
World
Tool
Workobject
Can Jog the Robot in Incremental steps.
Joystick Control
Linear Robot Motion
Joystick Control
Reorienting the Tool
Joystick Control
Axis by Axis Robot Motion
Joystick Control
Creating a New Program
Press the program key to open the program window
Choose File: New
If there already is an unsaved program, answer the

displayed dialog and press File: New again
Specify the new name for the program
Choose OK to confirm
A program with only one empty main routine is

created
Loading an existing program
Press the program key to open the program window
Choose File: Open
Press Unit until the right mass memory unit is

displayed
Mark the desired program or directory with the cursor

and press Enter to select
Choose OK to confirm
The program will be loaded
ModPos
ModPos - Modifying the position in a positioning instruction
e.g. MoveL.
Move
robot to desired position
Select
the instruction to be changed
press
the function key ModPos
Cutting
Cutting - Selecting one or more instructions, deleting them
and placing them in memory.
Move
cursor to instruction or use Mark to Select a

group of instructions
Choose
Can
EDIT : Cut
then be pasted anywhere
Copying
Copying - Selecting one or more instructions, copying
them and placing them in memory.
Move
cursor to instruction or use Mark to Select a

group of instructions
Choose
Can
EDIT : Copy
then be pasted anywhere
Pasting
Pasting - placing what ever instructions have been stored
in memory into the program.
Move
cursor to instruction where you wish to

place the instruction/s
Choose
EDIT : Paste
Sometimes
asked if you want to paste before or

after an instruction, default is after
Marking
Marking - Selecting one or more instructions.
Move
cursor to top/bottom of the list of instructions
Choose
EDIT : Mark
Move
cursor up/down until all lines that are wanted

are selected
Can
now Cut, Copy or Delete selection
Automatic Mode
Automatic mode is used to execute ready made programs
Figure 33 Dialog box used to confirm a change from manual to automatic mode.
Automatic Mode
Press OK. You have now changed to automatic mode and
the Production window appears on the display (see Figure

34).
Automatic Mode
Press the Motors On button on the operators panel.
Start the program with the Start function key.
Stop the program with the STOP button on the teach
pendant unit.
Switch back to manual mode
Error Message
If an error occurs, an error message will be displayed in plain

language on the teach pendant . If several errors occur
simultaneously, the error that occurred first will be selected.
An error message is displayed in plain language as soon as an error occurs
Languages & Messages
ERROR MESSAGES
Press _______
Log
to return to previous page.

ERROR MESSAGES
There are 8 categories of errors:
Category
Error #
Description
Operational
1X,XXX Status Information
System 2X,XXX Safety Circuits

Hardware
3X,XXX Circuit Board Failure
Program
4X,XXX Program Execution Problem
Motion 5X,XXX Movement Problems

Operator
6X,XXX Programming Unit Handling
I/O Comm.
7X,XXX Comm. Error to I/O Board
Internal
N/A
System Software Error

ERROR MESSAGES
A ________
of error messages is kept so you can look
LOG
at the last errors that the system has had.
The path that will take you to the ERROR LOGS is:
MISC. : SERVICE : VIEW : LOG

To Save Error Log:
Misc: Service: View: Log:
File: Save all Logs as:

ERROR MESSAGES
You can also erase one or more of the logs. While the cursor
is highlighting one of the error categories in the log screen,
press;
SPECIAL: ERASE LOG OR ERASE ALL
LOGS
To set system Date and Time:
Misc: Service: View:

2-Date and Time:
Coordinate Systems
z
Wrist Frame
y
Tool Frame
y
z
z
x
x
Base Frame
Programmed
position
y
World Frame
OBJE
CT
x
Work Object
USER
Coordinate systems
Z
Y
TOOL COORDINATES
Y
X
BASE COORDINATES
OBJECT COORDINATES
Y
Y
USER COORDINATES
Y
WORLD COORDINATES
X
Coordinate Systems Benefits
Tool Coordinate System
Defines the TCP and orientation of a tool
Necessary to run the robot (the TCP) in linear movements
The tooldata may be changed, reflecting a worn tool
Makes it possible to change tool, without changing the

program
Makes tool relative movements possible
Defines the work place for the robot
Makes it possible to move the whole workplace (a fixture)

without changing the program
Makes it easy to use a program, made on one robot, in

another robot with different workplace. Change the
workobject, not the program.
A program for an object may be displaced with search

function, to find the current location
Tool Centre Point

Tool Mounting
Flange
+Y
+X
Relative Directions X, Y & Z.
+Z
Tool Centre Point
Position & movement of robot always related to TCP.
Defined as being somewhere at the end of the tool.
Many can be defined but only one active at any one time.
Can be programmed manually but only if accurate data.
Normally use robot to define TCP.
If tool is damaged or replaced, dont change program just redefine the

tool.
Tool Centre Point
3 Methods of tool Definition
4 point TCP with 4 approach points.
5 point TCP & Z with 4 approach points and 1 elongator

point to define Z direction of tool.
6 point TCP& ZX with 4 approach points & 1 elongator for Z

direction & 1 for X direction .
4 Point TCP
No rotation about X, Y or Z
5 Point TCP
Z direction defined
5 Point TCP Spray gun
Z direction defined
6 Point TCP Welding gun
Both X and Z defined
6 Point TCP - Water jet Application
TCP
.
Water jet
TCP Definition - Simple
3
4
1
1
2
4
3
2
Plan view
TCP Definition - Complex

5
3
6
X Elongator
Z Elongator
X
2
Y
Base
coordinate
direction
Tool Centre Point Definition Method

In The Program Window
Menu : View : Datatypes
Cursor to tooldata and press Enter ().
Press the Function Key New.
Press Enter () to name your tool and then press OK.
Press Decl, List Key (

Twice.
Menu : Special : Define Coordinates
Press Enter () to choose TCP method 4, 5 or 6 then OK.
List Key (
) down, you can now enter your positions by moving the robot and
pressing ModPos.
) and move your cursor down to input mass in kg, then OK
Press OK and note the Mean and Max error, below 1 for each is preferable. Press OK.
In The Jogging Window.
Cursor to Tool, press Enter (), select your TCP and then
press OK to activate your TCP.
Defining TCP By Using The Robot
Jog the robot to the fixed tip with four different

orientations and in different directions (not in same
plane as in fig):
Defining TCP By Using The Robot
Open window by using View: Data Types
Select the type tooldata and press Enter
Choose Special: Define Coord
Modified
-
= Position defined
If error is acceptable press OK
= No Position defined
If error is too large, press Cancel

and redefine.
All program positions are attached to a work object

Wobj0 is the default coordinate system
It is advisable to use custom work objects
z
p10
y
Base
Wobj0
(0,0,0)
(900, 60, 500)
Work Objects
Custom Work Object
X1
Object
frame
User
frame
World
Work Objects contain both User and Object Frames
Work Object Frames
p10
(200, 0, 450)
(400, 0, 50)
World
User
(300, 60, 0)
Object
Work Objects and External Axis

Workobject disconnected from robot world
and attached to mechanical unit
Object frame may be transposed
from its User frame
Defining a Work Object frames
World
World
User and Object Coordinate Systems are usually both defined

at the same position.
1
bj
X
O
W
Work Objects
O
W
Y
X
2
j
b
Work Objects
WObjData is used to describe the area that the robot

welds, processes, moves within etc.
If position Data is entered manually, the values can be

taken from a drawing.
Programs can be reused quickly following changes in

the robot installation e.g. if a fixture is moved, just
redefine user coordinate system.
Variations in how the Work Object is attached can be

compensated for (using search and a sensor).
Robot can be jogged along the axes of the work object.
Work Object Definition Method

In The Program Window
View : Datatypes
Cursor to Wobjdata and press Return.
Press the Function Key New.
Press Return to name your work object and then press OK Twice.
Special : Define Coordinates
Move cursor up and down and press Return to choose 3 point method for User
and NoChange Object.
List Key down, you can now enter your positions by moving the robot and
pressing ModPos.
Press OK.
In The Jogging Window.
Cursor to Wobj, press Return, select your work object and then press OK to
activate it.
Robot Calibration
Robots delivered with all axis motor calibrated.
Motor resolver value is store in Manipulator system

parameter (Manipulator -> Motor Calibration)
It is recorded on Resolver value sticker on

manipulator
Two type of calibration procedure to robot which is

Fine Calibration and Revolution Counter Update
Calibration
Fine Calibration
Calibrate when resolver value change by
Change/dismentle motor
Change gearbox/gear
Revolution Counter Update
Counter update when resolver value change by
Battery discharged
Resolver error
Resolver signal interrupt
Robot axis moved with control system
disconnected
Calibration I-Mark
Revolution Counter Update
Press the Misc. Window key

Select Service in the dialog box shown on the display
Press Enter, and then choose View: Calibration
The robot will be in Unsychronized status if one of the
axis resolver counter is not updated
Choose Calib: Rev. Counter Update
Press function key All or Incl. to select not updated axis
Jog robot to calibration I-mark position (attached)
Confirming by pressing OK and press OK again to start
the update process
Check the calibration by using instruction MoveAbsJ
MoveAbsJ
Create routine rCalib

Find the instruction in IPL2, Motion Adv
Insert instruction,
MoveAbsJ *, v1000, z50, tool0
Move the cursor to block the * and choose Edit: Value
Change all the joint axes data to Zero (0)
Press OK to confirm the changes
Switch to Test mode and move the PP to the above
instruction
Execute the instruction by press FWD
After robot go to it calibration position, check robot IMark
What is a Program?
A program consists of instructions

and data, programmed in the RAPID
programming language, which control
the robot and peripheral equipment in a
specified way.
The program is usually made up of three
different parts:
a main routine
several subroutines
program data.
In addition to this, the program
memory contains system modules.
Creating a new program
Press Here!
Choose File: New.
If the robot is already loaded with

a program which has not been
saved, a dialog box appears and
you will be asked whether you
want to save it or not.
Specify the new name of the

program in the dialog box that
appears.
Choose OK to confirm.
A program with only one empty

main routine is created.
Loading an existing program
Here!
Here!
Choose File: Open.
If necessary, change the mass

memory unit by pressing Unit
until the correct unit is displayed.
Select the desired program.

Move up or down in the directory
by using either .. (up), or the
desired directory (down) and
press Enter .
Choose OK to confirm.
Tip: If there is an error in the

program, this error will be
displayed if you choose File:
Check Program
What is a Module?
Program Memory
Program Module(s)
Program Data
Main
Routine
Routines
System Module(s)
Program Data
Routines
What is a Module?
Program Memory
Program Module(s)
Program Data
Main
Routine
Routines
Program Data
Routines
System Module(s)
Program Data
Routines
The Internal Structure of Modules

%%%
VERSION:1
LANGUAGE:ENGLISH
%%%
MODULE EX1
CONST robtarget p3:=[[1266.11,-44.68,379.91],[0.567059,0.054467,0.821577,0.022118],[0,0,CONST robtarget p2:=[[1270.77,-93.78,386.13],[0.567071,0.054457,0.82157,0.02211],[-1,0,CONST robtarget p1:=[[1312.4,-132.16,381.39],[0.567077,0.054431,0.821568,0.02209],[-1,0,-
PROC main()
MoveL p1,v1000,fine,tool0;
ENDPROC
ENDMODULE
Modules
A module is a group of routines and data.
A program module that contains a main routine is the main

program module, otherwise just a sub program module.
System modules are always present in memory and can be

used to save your default data and routines.
Filename extensions are:

XXXXX.PRG
= Program Module
XXXXX.MOD
= Program Module (no MAIN)
XXXXX.SYS
= System Module
Saving programs that use modules
When a program is saved using FILE : Save Program, all program

modules in memory are saved with the main program module into
one amalgamated file.
(.PRG)
ABB
Program Module
(.MOD)
DrawSQ
Program Module
(.MOD)
DrawTri
Program Module
ABB.PRG
Opening programs that use modules

When a program is opened using FILE : Open, any modules that have
originally been saved with the program are loaded in and separated out.
They can still be saved separately.
(.PRG) ABB
Program Module
(.MOD) DrawSQ
Program Module
(.MOD) DrawTri Program Module
ABB.PRG
Saving Modules
When a module is saved using FILE : Save Module, the selected module in
memory is saved as a single .MOD or .SYS module file.
(.PRG) ABB
Program Module
(.MOD) DrawSQ
Program Module
(.MOD) DrawTri Program Module
(.SYS) User
System Module
DrawSQ.MOD
Programming
Adding in New Instructions
If a new instruction is added, it is placed after the instruction that is

selected.
Select the place where

you want the new
instruction to be added.
Call up one of the

instruction pick lists by
choosing the appropriate
pick list from the IPL1 or
IPL2 menu.
If want to call up the

instruction pick list that
was used most recently,
choose Edit: Show IPL.
Programming (1)
Moving and Copying Instructions
Select the instruction you wish to move or copy. To select

several instruction, choose Edit: Mark.
Choose Edit: Cut (move) or Edit: Copy.
Indicate where you wish to add the new instruction.
Choose Edit: Paste.
In the Program Instruction window, copy and paste can also

be selected using a function key.
Programming (2)
Procedures and Functions
A procedure is a number of instructions, put together in a box

with a specific name
This box may be called from the main routine (or any), and the
content of instructions will be executed
The call of the procedure is like an instruction:
MoveL p100, v100, z10, tool1;
FetchPart;
MoveL p110, v100, z10, tool1;
A function is another box of instructions, used to calculate a
value:
reg1 := Dist (p110, p100);
Routine is the common term for both procedures and functions
Programming (3)
More readable program
Better structured program
The code can be reused in several different parts of the
program
Program creation is easier, the different routines may be

created and tested separately
The robot may be customized by creating application
specific routines
Programming (4)
Program Structure
Procedure main
...
fetch_part
leave_in_machine
process_part
fetch_fr_machine
leave_part
...
procedure fetch_part
MoveJ *,vmax,z50,tool1;
MoveL *, v1000,z30,tool1;
MoveL *,v200,fine,tool1;
grip;
MoveL *,v200,z30,tool1;
grip
Set gripper;
WaitTime 0.3;
release
Reset gripper;
WaitTime 0.3;
Programming (5)
A rapid routine can be:
Procedure, ex:
fetch_part;
SpotL p100,vmax,spot10,gun7,tool7;
Function, ex:
reg1:=circ_rad(p1,p2,p3);
reg2:=max(a,b,c);
Programming (6)
Names - identifiers
Variables names must have:
- max. 16 characters
- first character must be a letter!
- only letters, digits and underscores
RAPID keywords cannot be used as variable names.

It is absolutely desirable to use meaninful names suggestive of
the entity they represent.
Note! Not case sensitive, i.e foobar is equal to FoObAr
What is a Routines?
There are three types of routines
(subprograms): Procedures, Functions and
Trap:
- Procedures do not return a value and

are used in the context of instructions.
- Functions return a value of a specific
type and are used in the context of
expressions.
- Trap routines provide a means of dealing
with interrupts.
What is a Routines? [1]
A routine can contain routine declarations (including parameters),

data, a body, a backward handler (only procedures) and an error
handler.
Routine declarations cannot be nested, i.e. it is not possible to

declare a routine within a routine.
What is a Routines? [2]

Procedure main
...
fetch_part
leave_in_machine
process_part
fetch_fr_machine
leave_part
...
MoveJ
*,vmax,z50,tool1;
procedure
leave_in_machine
procedure process_part
grip;
procedure fetch_fr_machine
procedure leave_part
release;
grip
Set gripper;
WaitTime 0.3;
release
Reset gripper;
WaitTime 0.3;
Routines
Before you start to program, you should think out the structure first.
Repetitive instruction sequences that occur frequently in the program,
such as gripper handling, should form their own routines.
Routines separate the program into smaller more easily understood

parts that can then be called anywhere in the program.
You have Max 16 characters allowed for naming a routine so you
should give them meaningful names such as DrawCircle, CutSquare
and PickPart
The Program Routines Window
Choose View: Routines to

open the window.
The window displays all the

routines in your system and, if
there is a function present, also
the type of data returned for that
function.
Here!
Creating New Routine
Here!
Here!
Here!
Choose View: Routines to

open the window.
Press function key New.
Change the name by pressing

Enter and specify a new name
If you want a normal subroutine

(procedure) without any
parameters, you should finish
here by pressing OK. In cases,
the characteristics of the routine
must be defined.
Creating New Routine (1)
Here!
In cases, the characteristics of

the routine must be defined.
Press the function key Decl_.
Change the characteristics of the

routine by selecting the
appropriate filed.
Routines
Main
MoveJ *,v5,z1,tcp;
Square;
MoveJ *,v5,z1,tcp;
MoveL *,v5,z1,tcp;
MoveJ *,v5,z1,tcp;
MoveJ *,v5,z1,tcp;
Square;
Main routine
Square
Circle
MoveJ *,v5,z1,tcp;
MoveL *,v5,fine,tcp;
MoveL *,v5,z1,tcp;
MoveL *,v5,z1,tcp;
MoveL *,v5,z1,tcp;
Circle;
MoveL *,v5,z1,tcp;
MoveJ *,v5,z1,tcp;
MoveJ *,v100,z1,tcp;
MoveL *,v5,fine,tcp;
MoveC *,*,v5,z1,tcp;
MoveC *,*,v5,fine,tcp;
MoveL *,v5,z1,tcp;
MoveJ *,v100,z1,tcp;
Sub routines
Duplicating a routines
Here!
Choose View: Routines.
Select the routine to be

duplicated.
Press the function key Dupl.

Change the name by pressing
Enter and specify a new
name
Here!
Choose OK to be confirm the

duplication.
Path Following Exercise

Start / Finish
Start / Finish

Start / Finish
Direction
Main Routine
MoveJ pHome;
Home Position
MoveJ pSafe;
Safe position
Outside;
Routine to seal outside edge
Oval;
Routine to seal oval shape
Circle;
Routine to seal circle shape
MoveJ pSafe;
Safe position
MoveJ pHome;
Home Position
Data
Data
There are three kinds of data:
Variables
Constants
Persistents
Data
Variables - VAR
A variable is an entity used by the program to store values in

the computation.
A variable can be assigned a new value during program

execution.
Example:
VAR num mint;
VAR num cherry := 100;
Data
Constants - CONST
A constant is an entity whose value does not change during

program execution.
All constant declarations must have an initial value.
Example:
CONST string str:=ABB Robotics;
Data
Persistent - PERS
A persistent can be described as a persistent variable.
An update of the value of a persistent automatically cause

the
initialisation value of the persistent declaration to be
updated.
When the program is saved the initialisation value of any
persistent
declaration reflects the current value of the persistent.
All persistent declarations must have an initial value.
Example:
PERS bool dirty:=FALSE;
Note! A persistent may only be declared as module data.
Data
Changing of data
System
Event ->
Data
V
Constant
Warmstart
Open
Start
program Program
(MoveP
P
to Rout)
Unchang Initiated Initiated
ed
Start
Program
(After
Cycle)
Start
Program
(After
Stop)
Start
ModPos
Program
(MoveP
Pto
cursr)
Unchang Unchang Unchang Changed
ed
ed
ed
Assign- Change
ment in in Data
program Window
Changed Changed
(not Init (also Init
value)
value
can be
changed)
-
Not
Changed
possible
to
change
Unchang Unchang Unchang Unchang Changed Changed Changed
ed
ed
ed
ed
Persistent
Unchang Initiated
ed
Variable
Unchang Initiated
ed
Initiated
Unchang Unchang Unchang Not

ed
ed
ed
possible
to
change
Interrupt
definition
Unchang deleted
ed
deleted
Unchang Unchang Unchang ed

ed
ed
Data
Speed Data
Speed data is used to specify the velocity at which

both the robot and the external axes move.
It defines the velocity:
At which the tool centre point moves.
Of the reorientation of the tool.
At which linear or rotating external move.
Example :
V100 = 100 mm/s
Data
Zone Data
Zone data is used to specify how a position is to be

terminated, i.e. How close to the programmed
position the axes must be before moving towards
the next position.
A position can be terminated either in the form of

a stop point or a fly-by-point.
Path Programing
STOP POINT
Means that the robot and external axes must reach

the specified position (stand still) before program
execution continues with the next instruction.
FLY-BY- POINT
Means that the programmed position is never attained.
The direction of the motion is charged before the position

is reached
Path Programing
What is an instruction?
An instruction defines a specific task that is to be carried out

when instruction is executed, for example
Moving the robot
Setting an output
Changing data
Jumping within the program
Instructions comprise an instruction name and a number of arguments.
The name specifies the principal task of the instruction and the
arguments specify the characteristics.
Example:
MoveL p1,v500,fine,tool1
Moves the TCP linearly to the position p1. The arguments, v500, fine and tool1,
specify the current speed, position accuracy and tool.
What is an instruction? (1)
Getting more information about an instruction
Selecting the desired instruction and press Enter
MoveJ - Moves the robot by joint movement
MoveJ is used to move the robot quickly from one

point to another when that movement does not
have to be in a straight line.
MoveJ - Moves the robot by joint movement

Type of path
- J = Joint
Speed specified in speed data

v100=100mm/s
Tool (TCP)
MoveJ p10, v100, z10, tool1

Destination position
- *
= stored in instruction
- P10 = stored in position data p10
Zone size specified in zone data z10 = 10mm
MoveC - Moves the robot circularly
MoveC is used to move the tool centre point

(TCP) circularly to a given destination.
During the movement, the orientation normally

remains unchanged relative to the circle.
MoveC - Moves the robot circularly

Type of path
C = circular
Circle position
- *
MoveC p20, p30, v100, z10, tool1

- *
MoveAbsJ - Moves the robot to an absolute joint

position
MoveAbsJ (Move Absolute Joint) is used to move the robot

to an absolute position, defined in axes positions.
The final position of the robot, during a movement with

MoveAbsJ, is neither affected by the given tool and work
object, nor by active program displacement.
However, the robot uses these data to calculating the load,

TCP velocity, and the corner path.
The robot and external axes move to the destination

position along a non-linear path.
All axes reach the destination position at the same time.
MoveAbsJ - Moves the robot to an absolute joint

position
Type of path
- J = Joint
Speed specified in speed data

v1000=1000mm/s
Tool (TCP)
MoveAbsJ p10, v1000, z10, tool1
- *
Zone size specified in zone data z10 = 10mm
ProcCall - Calls a new procedure
A procedure call is used to transfer program execution to

another procedure.
When the procedure has been fully executed, program

execution continues with the instruction following the
procedure call.
ProcCall - Calls a new procedure [1]

Procedure main
...
fetch_part
leave_in_machine
process_part
fetch_fr_machine
leave_part
...
grip;
grip
Set gripper;
WaitTime 0.3;
release
Reset gripper;
WaitTime 0.3;
Comment
Comments are used to make the program easier

to understand
Comments have no influence on the program
execution
! This is a comment
Exercise 1
Start up the robot system under consideration of the safety procedures
Choose the JOG window on the teach pendant
Choose the following settings
Coordinate System
Base
Tool
tool0
Work object
workobj0
Move each joint of the robot in joint mode
Move one axis all the way to the limit of the working limit. Confirm the error
message and move in the opposite direction
Move the robot in linear motion mode
Change the speed of the movement by selecting incremental
Move the robot by selecting reorientation mode
Exercise 2
1. Select the Program Editor, choose Task and Program.
2. Select File and choose New Program. (Refer to page 151)
3. Write the name of the program on the numerical keyboard, EX2 and press
OK
4. Press the menu key Add Instruction.
5. Choose Move instruction according to the program example (next page)

6. The positions p10 - p50 shall be programmed so that when executing the
program, the pencil moves linearly on the table except from p50 to p10.
7. Select QuickSet Menu and set the speed adjustment (-%) to 10%. Run the
program in Manual mode (<250 mm/s), first step-by-step forwards (FWD)
and then continuously (Start)
PROC main()
MoveJ p10, v500, fine, tool0

MoveL p20, v500, fine, tool0
p40
p50
ENDPROC
p10
p30
p20
Exercise 3
1. Continue from the EX2
2. Create and define a tool called tool1 - using 4 point definition (Refer to page 128
134)
3. Exchange all tool0 arguments in the program to tool1 and run the program
What happened and why?
...
4. Reprogram all the positions to the right place by using the key Modify Position and
test run the program again
5. Increase the speed (+%) by steps to 50% while running the program in continuous
mode. To reach a higher speed the Operating Mode Selector has to changed to 100%
Observe the robot behavior (the speed) at the positions programmed
.
.
Exercise 3 [1]
6. Change the zone argument from fine to z30 for positions p20, p30 and p40.
Set the speed correction (-%) to 10% and run the program, first step-bystep (FWD) and then in continuous mode (Start)
Observe the difference in movement at the z30 positions
..
7. Change the speed for position p30 to v300 and for p40 to v1000
Run the program with different speed correction settings and check the path
performance at the fly-by positions.
Is there a difference?
.
8. Insert a time of waiting for 5 seconds (WaitTime) after the instruction for p40.
Run the program and notice the robot position when the waiting is executed
Exercise 3 [2]
9. Remove the instructions for the waiting and p50 from the program.
Run the program again and notice the new behavior.
10. Change the instructions for p20 and p30 from MoveL to MoveJ
Observe the movement change when executing the program
.
11. Insert the position p50 again and put an obstacle between p30 and p40,
which the robot has to pass in a proper way, by programming four new
instructions (MoveL) with suitable speed and zone size. (p60, p70, p80,
p90)
Run the program and notice the robot position when the activation of the
output starts.
Exercise 3 [3]
12. Change the zone argument for p30 to fine
Run the program again and watch the difference compared to item 12
.
13. Perform a backward execution of the program (BWD), watching the
movements and what is happening at the logical instruction.
..
14. Save the program with the new name of EX3
Exercise 4
1. Which group of coordinate systems are available in the robot system?
A)
B)
C)
D)
E) ...
2. Re-open program EX2
3. Create and define a workobject called wobj2 (in PERS datatype)

(User coordsys = Base coordsys)
4. Modify the program so that it is uses the workobject wobj2 in the Move
instruction (re-teach the point)
5. Create another workobject wobj3 (with location show in next page)
Exercise 4 [1]
wobj3
wobj2
+x
+x
+y
+y
Exercise 4 [2]
6. Change the Workobject in Move instruction from wobj2 to wobj3
Observe the movement change when executing the program
.
7. Save the program with the new name of EX4
Exercise 5
1. Create a routine according to the flowchart below and call EX5
2. Add an instruction to the routine.
3. Complete the program by putting in another routine.
4. Add a position (phome) at the beginning of the program.
Triangle
Routine
Square
Routine
Circle
Routine
Exercise 5 [1]
PROC Square()
MoveJ pHome, v500, z20, tool0;
MoveJ pHome, v500,z20,tool0;
MoveL sq1, v150, fine, tool0;
MoveL c1, v500, z20, tool0;
MoveC c2,c3, v200, fine, tool0;

MoveJ pHome, v500, z20, tool0;
ENDPROC
PROC Triangle()
PROC Cricle()
MoveJ tri1, v500, z20, tool0;

MoveL tri2, v200, fine, tool0;
MoveL tri3,v200,fine,tool0;
MoveL tri1, v200, z20, tool0;
ENDPROC
MoveC c4,c1,v200,fine,tool0;
ENDPROC
Exercise 6
1. Continue the EX5.
2. Using the procall method to link all the routine.
Main
procedure
Triangle
procedure
Square
procedure
Circle
procedure
Exercise 6 [1]
PROC main()
Circle;
Square;
Triangle;
ENDPROC
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Basic Programing S4

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ABB Malaysia - 1 Jun 16, 2015

ABB Basic Programming Training - 2 Jun 16, 2015

1.1 System Overview

ABB Basic Programming Training - 3 Jun 16, 2015

1.2 Basic Operation

Starting the System

Working with Windows

Jogging the Robot Using Joystick

ABB Basic Programming Training - 4 Jun 16, 2015

2.1 Robot Coordinate System

Tool Coordinate System

Work Object Coordinate System

Calibration and Counter Update

Backup & Restore

ABB Basic Programming Training - 5 Jun 16, 2015

2.2 Program Structure and Overview

Procedure and Functions

ABB Basic Programming Training - 6 Jun 16, 2015

3.2 Intermidiate Instruction

Move with Offset

ABB Basic Programming Training - 7 Jun 16, 2015

3.4 Advance Instruction

ABB Basic Programming Training - 8 Jun 16, 2015

3.4 Advance Instruction

STOP AND EXIT

ABB Basic Programming Training - 9 Jun 16, 2015

ABB Basic Programming Training - 10 Jun 16, 2015

ABB Basic Programming Training - 11 Jun 16, 2015

A robot is a combination of two principal

ABB Basic Programming Training - 12 Jun 16, 2015

Please observe each axes movement

ABB Basic Programming Training - 13 Jun 16, 2015

Base rotates 180

ABB Basic Programming Training - 14 Jun 16, 2015

Teach Pendant and Operator Panel

The teach pendant and operator panel are

ABB Basic Programming Training - 15 Jun 16, 2015

S4C Control System

The controller is consist of 4 principal

AUTO (Production Mode)

MANUAL (Teach Mode)

ABB Basic Programming Training - 16 Jun 16, 2015

MANUAL 100% (Teach Full Speed)

ABB Basic Programming Training - 17 Jun 16, 2015

MANUAL REDUCED SPEED MODE (Programming

ABB Basic Programming Training - 18 Jun 16, 2015

Used to test run the robot program at full programmed

ABB Basic Programming Training - 19 Jun 16, 2015

MOTORS ON (an illuminated push-button) is used to start the

ABB Basic Programming Training - 20 Jun 16, 2015

ABB Basic Programming Training - 21 Jun 16, 2015

The HOUR METER is used to keep track of

ABB Basic Programming Training - 23 Jun 16, 2015

Enabling device is a press switch with three positions

The switch must be in the middle in order to activated the

All robot movement will immediately stop if the switch is

Teach Pendant (cont 2)

The joystick is used to jog (move) the robot manually; e.g.

ABB Basic Programming Training - 24 Jun 16, 2015

Display all information during programming, to change

Can accommodate 16 lines.

Each line can accommodate 40 characters..