User Manual: Promia 50 Application - Material Handling

The heart
of Robotics
ABB
User Manual
Promia 50 application Material Handling
IRC5
RDNU0006_F_MH-Promia50_Eng.doc
User Manual
Promia 50 application Material Handling
Document ID: RDNU0006
Revision: F
This document is intended for recto/verso printing.

Document based on model RDDI0013_E
The information in this manual is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of
guarantee or warranty by ABB for losses, damages 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, and contents
thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be
prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
ABB
ABB France s.a.s
Robotics Division
Rue de lEquerre
ZI des Bthunes
95310 Saint-Ouen lAumne
FRANCE
RDNU0006 Revision F
Table of Contents
Overview ......................................................................................................................................5
Product Documentation, M2004 ...................................................................................................7
Promia Documentation.................................................................................................................8
1 Safety
1.1
1.2
1.3
About the Safety section ...................................................................................................9

Safety standards applicable to IRC5 ...............................................................................10
Safety terminology ..........................................................................................................11
2 Welcome
2.1
2.2
2.3
2.4
13
About the Welcome section ............................................................................................13

What is Promia?..............................................................................................................14
Integrator customizations ................................................................................................16
Terms and concepts used in this manual........................................................................17
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
Robot program and path principles .....................................................................17

Repositioning and recycling principles ...............................................................19
Commands and events.........................................................................................21
Tooling commands and events ............................................................................21
Material handling management ...........................................................................22
Debug mode ........................................................................................................23
3 Organization of application software

3.1
3.2
3.3
3.4
3.5
3.6
25
General information.........................................................................................................25
Loading the application software.....................................................................................25
Software architecture ......................................................................................................27
Organization of memory..................................................................................................28
Organization of RAPID files ............................................................................................30
Contents of the Site directories .......................................................................................31
3.6.1 Common base modules .......................................................................................31

4 Operating principles
4.1
4.2
4.3
4.4
4.5
General controls of the robot controller ...........................................................................33

Main menu of FlexPendant .............................................................................................34
Considerations related to single and multi-robot environments.......................................35
Running the program ......................................................................................................38
Production modes ...........................................................................................................40
4.5.1
4.5.2
4.5.3
4.5.4
4.6
4.7
33
"Production enabled" and "Production disabled" modes.....................................40

Active commands according to operation modes................................................41
Move to Safe and Move to Home commands .....................................................41
Catching and priority of program codes ..............................................................45
Principles relative to actions and checks attached to a position......................................47

Continuous monitoring ....................................................................................................48
4.7.1 Dynamic monitoring............................................................................................48

4.7.2 Error management ...............................................................................................49
4.8
Behaviors in cases of exception......................................................................................50
4.8.1 Behavior during manual jogging .........................................................................50

4.8.2 Behavior in case of repositioning ........................................................................50
4.8.3 Behavior in case of recycling ..............................................................................50
5 Man-Machine Interface
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51
Overview
5.1
5.2
5.3
General description of the screen container....................................................................51

Choice of "Common Features" screens ..........................................................................53
Production screen ...........................................................................................................55
5.3.1 Program area details ............................................................................................55

5.3.2 Message area details............................................................................................56
5.4
Error messages...............................................................................................................59
5.4.1 Common base application messages ...................................................................59

5.5
5.6
Operator panel screen ....................................................................................................65

Promia information screens ............................................................................................66
5.6.1
5.6.2
5.6.3
5.6.4
5.6.5
5.7
General description of the information screen.....................................................66

Part detection screen............................................................................................68
Sequence screen ..................................................................................................70
PLC and Tool Event Screens...............................................................................76
PLC and Tool Command Screens .......................................................................78
Backup screen ................................................................................................................79
5.7.1 General description of screen ..............................................................................80

6 Editing paths
6.1
6.2
6.3
General information.........................................................................................................83
Insertion of a specific instruction of the application .........................................................84
Inserting a Common base instruction........................................................................85
7 Actions on paths common to all processes

7.1
7.2
7.3
83
87
Programming anti-loop functions.....................................................................................87

Giving information about active path and active robot program ......................................89
Programming PLC commands ........................................................................................90
7.3.1 SendPlc instruction ..........................................................................................90

7.3.2 MoveSendPlc instruction.................................................................................91
7.4
Programming events .......................................................................................................92
7.4.1 PlcEvent instruction ......................................................................................92

7.4.2 MovePlcEvent instruction ..............................................................................93
7.5
Programming tool commands .........................................................................................94
7.5.1 SendTooling instruction.................................................................................94

7.5.2 MoveSendTooling instruction .......................................................................95
7.6
Programming tool events ................................................................................................96
7.6.1 ToolingEvent instruction ..............................................................................96

7.6.2 MoveToolingEvent instruction.....................................................................97
7.7
Programming handling sequences..................................................................................98
7.7.1 GripperAction instruction............................................................................99

7.8
Programming part detection functions...........................................................................100
7.8.1 CheckPart instruction ...................................................................................100

7.9
Programming the dynamic monitoring functions ...........................................................102
7.9.1 MonitorInputs instruction..........................................................................102

8 Service programs
8.1
General information.......................................................................................................105
9 Index and appendices

9.1
9.2
105
107
Index .............................................................................................................................107
Table of figures .............................................................................................................109
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Overview
Overview
About this manual

This manual contains detailed instructions on how to use of the material handling
functions of the Promia application.
The manual gives the characteristics of the basic application, orientated to
handling.
Usage
This manual should be used during operator training workshops, and when creating
or modifying programs based on the Promia application software.
Who is this manual intended for

This manual is intended for:
Operators
Maintenance technicians
Robot programmers and integrators
Prerequisites
The reader must:
Be familiar with use of the IRC5 FlexPendant
Be trained in basic robot programming.
References Product Documentation

Reference
Document
Product Manual, procedures

Product Manual, references
Startup - IRC5 and RobotStudio Online
IRC5 3HAC 021313-001

IRC5 3HAC 021313-001
3HAC 021564-001
How to read this manual

To facilitate reading this manual, special formatting is used to indicate different
types of information.
Text that is...
is written with...
Example
names on elements in the

user interface, like
menus,
dialog boxes and buttons
bold letters
In the Open File dialog

box, click OK
names on keyboard keys
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capital letters
To open the help,

press the F1 key.
Overview
quotes from computer
or output, like error
messages, written RAPID
instructions and other
computer code
variables in quotes from
computer input or output,
like error messages,
written RAPID instructions
and other
computer code
Hypertext links to other
information topics
References to other
information topics
monospace letters
MoveJ
Italic monospace
letters
PROC
RoutineName()
blue italic letters
italic letters
See The RobotStudio

Online Operators
Manual
See the RAPID reference
manual for further
information.
Revisions
Revision
A
B
C
D
E
F
Description
First issue, December 2005
Updated with new MMC interface, December 2006
Update of master document 02/2007
Update of master document Add new simplified backup
functionality. 11/2007
Miscellaneous 04/2008
Add warnings about B-Start et recycling 05/2008
RDNU0006 Revision F
Product Documentation, M2004
Product Documentation, M2004
General information
The robot documentation is divided into different categories. The list is based on
the type of information contained in each document, whether the products are
optional or not. This means that each robot delivery will not contain all the
documents listed, but only those corresponding to the equipment supplied.
However, all the documents listed can be ordered from ABB. The documents listed
are valid for the M2004 robot systems.
Hardware Manuals
All hardware, robots and control cabinets will be delivered with a Product Manual,
which is divided into two parts:
Product manual, procedures
Safety information
Installation and commissioning (descriptions relative to mechanical

installation, electrical connections and loading system software)
Maintenance (descriptions of all required preventive maintenance

procedures, including intervals)
Repair (descriptions of all recommended repair procedures, including

spare parts)
Additional procedures, if any (calibration, decommissioning)
Product manual, reference information

Reference information (article numbers for documentation referred to in
Product manual, procedures, lists of tools, safety standards)
Part list
Foldouts or exploded views
Circuit diagrams
RobotWare Manuals
The following manuals provide a general description of the robot software and
contain the applicable reference information.
RAPID Overview: Overview of RAPID programming language
RAPID Reference Manual, part 1: Description of all RAPID instructions.
RAPID Reference Manual, part 2: Description of all RAPID functions, including
data types.
Technical reference manual System parameters: Description of system
parameters and configuration workflows.
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Promia Documentation
Application manuals
Specific applications (e.g. software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains the following information about:
The purpose of the application (what it does and when it is useful)
What is included (e.g. cables, I/O boards, RAPID instructions, system
parameters)
How to use the application
Examples of how to use of the application.
Operator manuals
This group of manuals is aimed at those having first hand operational contact with
the robot, i.e. production cell operators, programmers and troubleshooters.
This group of manuals contains:
Getting Started - IRC5 and RobotStudio Online
Operator manual - IRC5 with FlexPendant
Operator manual - RobotStudio Online
Troubleshooting manual for the controller and robot
Promia Documentation
General information
Promia is a family of application software intended for the IRC5 robot systems.
All of these software applications include a common part, linked to the material
handling process, on which a part specific to a process can be added.
For each process, the Promia documentation includes a user manual and an
integration guide. The information supplied for a given process always includes
the information relative to the handling process.
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1 Safety
1.1 About the Safety section
1 Safety
1.1
About the Safety section
Introduction to Safety
This section details the safety principles and the procedures to be applied when a
robot or a robot system is in operation.
It does 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 system.
Personnel safety
Any moving manipulator is a potentially lethal machine.
When running the manipulator, it may perform unexpected and sometimes
irrational movements. However, all movements are performed with great force and
may seriously injure any personnel and/or damage any piece of equipment located
within the manipulator working range.
Safety regulation
Before starting to work with the robot, make sure you are perfectly familiar with
the safety rules detailed in the Operator Manual IRC5 with FlexPendant.
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1 Safety
1.2 Safety standards applicable to IRC5
1.2
Safety standards applicable to IRC5
Safety standards
The robot fully complies with the safety standards specified in the European
machinery directives. The ABB robots controlled by the IRC5 comply with the
following standards:
Standard
EN ISO 12100-1
EN ISO 12100-2
EN 954-1
EN 775
EN 60204
EN 61000-6-4
(option)
EN 61000-6-2
EMC, generic emission

EMC, generic immunity
Standard
IEC 204-1
IEC 529
Description
Electrical equipment of industrial machines
Degrees of protection provided by enclosures
Standard
ISO 10218
Description
Manipulating industrial robots, safety
Manipulating industrial robots, coordinate systems and
motions
ISO 9787
Standard
ANSI/RIA
15.06/1999
ANSI/UL 1740-1998
(option)
CAN/CSA Z 434-03
(option)
10
Description
Safety of machinery, terminology
Safety of machinery, technical specifications
Safety of machinery, safety related parts of control
systems
Manipulating industrial robots, safety
Electrical equipment of industrial machines
Description
Safety requirements for industrial robots and robot
systems
Safety standard for robots and robot equipment
Industrial robots and robot systems - General safety
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1 Safety
1.3 Safety terminology
1.3
Safety terminology
Overview
This section describes the various types of warning which may be given during the
operations described in this manual. Each warning is explained in its own section
with:
A symbol for each hazard level (DANGER, WARNING or CAUTION)
and the type of hazard
A brief description of the result of the hazard if the operator/service
personnel does not eliminate the hazard
An instruction enabling the personnel to eliminate the hazard and perform
the operation manually.
Hazard levels
The table below defines the hazard symbols used in this manual.
Symbol
Designation
Danger
Danger
Warning
Warning
Electrical shock
Meaning
Warns that an accident will occur if the
instructions are not followed, resulting in a
serious or fatal injury and/or severe 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.
Warns that an accident may occur if the
instructions are not followed, that can lead
to serious injury, possibly 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.
The electrocution or electrical shock symbol
indicates electrical hazards which could
result in severe personal injury or death.
Electrical shock
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1 Safety
1.3 Safety terminology
Caution
Warns that an accident may occur if the

instructions are not followed, that can
result in injury and/or damage to the
product. It also applies to warnings of
risks that include burns, eye injury, skin
injury, hearing damage, crushing or
slipping, tripping, impact, fall from height
etc. Furthermore, it applies to warnings
that include function requirements when
fitting and removing equipment, where
there is a risk of damaging the product or
causing a breakdown.
Electrostatic
discharges (ESD)
The electrostatic discharge (ESD) symbol

indicates electrostatic hazards which
could result in severe damage to the
product.
Tip
Tip symbols direct you to specific

instructions, where to find additional
information or how to perform a certain
operation in an easier way.
Note
Note symbols alert you to important facts

and conditions.
Caution
Electrostatic
discharges(ESD)
Tip
Note
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2 Welcome
2.1 About the Welcome section
2 Welcome
2.1
About the Welcome section
Overview
The Welcome section provides an overview of the PROMIA application software.
The 5.x versions of this application software are intended for the IRC5 robot
systems, in both the single and multi-robot configurations.
This section describes the main Promia functions, as well as the concepts and
terms which will be used in this document.
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2 Welcome
2.2 What is Promia?
2.2
What is Promia?
Promia Description
The term "PROMIA" refers to the family of software applications organized
around a common base which defines the interfacing principles with a PLC and
the material handling functions.
The software applications derived from the common base include interfaces with
different processes and/or different specific equipments.
In particular, Promia can be delivered as a Promia Arc application, orientated
toward arc welding, and a PROMIA SRE application, orientated toward Spot
Welding on electrical welding guns.
Main components of basic application software
Promia Common Base

Safety
Functions
Applicative
Functions
Management of
Part Codes
Commands
events
Monitoring
User
Screens
Tooling
Control
Cabinet
Figure 1.
Tooling
Commands
and Events
Material
Handling
Functions
PLC
Gripper
&
Tool
Block diagram of PROMIA application software
The basic application software manages the interface with an industrial PLC in
order to handle the part codes, synchronizations through commands and events,
and error reporting through monitoring functions.
It also manages the interface with the grippers and tools through handling
sequences , also called "gripper actions" and part detection monitoring
functions.
Exchanges with a tooling control cabinet are managed by tooling commands and
events.
The safety functions consist of a pre-configuration for acknowledgement of remote
start requests.
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2 Welcome
2.2 What is Promia?
The applicative functions are the management of the movements to the "safe" and
"home" positions, and the management of the service requests that are local to the
robot controller.
The user screens display the information relative to the application software
functions. These screens are detailed later in this document.
In a multi-robot environment, the management of the part codes and the error
reporting are common and global for all the robots. On the other hand, the
commands, events and the handling interface are specific to each robot.
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2 Welcome
2.3 Integrator customizations
2.3
Integrator customizations
Integrator tasks
Promia is not directly operational in the form in which it is delivered and installed.
Promia is a programming frame, not an end-user application.
Promia becomes a customer final application once it has been customized by the
integrator; it is their job to define the robot paths and adapt the Promia functions to
the specific requirements of the user site.
The information required for customization is detailed in the Promia application
software integration guides.
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2 Welcome
2.4 Terms and concepts used in this manual
2.4
Terms and concepts used in this manual
Overview
This section describes the main concepts and terms used in this manual.
The description starts with the general concepts related to execution of the robot
paths and to the continuous monitoring performed by the application software,
followed by the terms related to the dialogue with the PLC, and finally, the terms
related to the various processes.
2.4.1 Robot program and path principles

Robot program and path principle
The various production tasks to be performed by a robot, or by a set of robots
controlled by a single robot controller, are selected in accordance with information
coming from the robot(s) environment.
The robot controller can receive work requests from different components:
The PLC, that sends part codes according to a pre-defined protocol,
A specific process equipment which requests a service operation (for

example, tip dressing for a welding gun or cleaning of a welding torch),
A service request, local to the robot controller, through a pushbutton, for

instance,
An external device (selector, for example).
The first three cases are handled on a standard basis by Promia. The fourth case
can be implemented by an internal code mechanism described below in the
manual.
Each requested task is executed as a robot program which is itself divided into
paths .
To facilitate installation control and maintenance, the various paths begin and end
by a fine point. They also include an "anti-loop" mechanism to ensure that they are
not executed as a loop without returning to the main robot program.
Significant positions and sequencing of robot programs

In principle, the various robot programs begin and end by a specific position
referred to as "home" position. The new program codes are only taken into account
on this point. The organization of the various robot programs then takes the form
of a "daisy" with the home position at its center.
It is also possible to terminate the robot programs outside this point; this function
is described in the Basic handling application software integration guides.
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2 Welcome
T_Service1
T_MoveToHome
Traj1
Program n1
Home
Position
Traj3
T_MoveToSafe
ctT
oS
a fe
Safe
Position
Traj2
Traj5
T_
Mo
ve
Dir
e
Traj4
Program n2
Figure 2.
Sequencing of paths ; daisy principle
The other significant position is the "safe" position which is a maintenance

position where technicians can perform maintenance operations on the robot
and/or its gripper or tool. This is also the starting point to get the cell ready for
production and the final point reached at the end of production.
There are thus three specific paths:
T_MoveToHome, which moves the robot from the safe position to the
home position, and is executed at production startup
18
T_MoveToSafe, which moves the robot back from the home position
to the safe position, and is executed at the end of production
T_MoveDirectToSafe, which moves the robot directly from its

current position (anywhere) to the safe position.
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2 Welcome
2.4.2 Repositioning and recycling principles
Description
When a robot has been stopped during its execution, there are two different ways
to resume the execution sequence:
The robot resumes its path, after possible physical repositioning toward
the position where the stop took place. This procedure is called "path
regain" or repositioning,
The robot does not resume the normal path, either because the operator,
after some manual jogging, is aiming directly at the next programmed
position, or because the operator, using the Debug menu in the Program
editor window, has placed the program pointer on an instruction
different from the current instruction. In both cases, the recovery
procedure is referred to as recycling.
Figure 3.
Debug menu
Programmed
position n+1
Progarmmed
position n+2
Recycling
Programmed
position n
Figure 4.
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Position where
the robot stopped
Recycling without manual jogging
19
2 Welcome
Current position
Recycling
Jogging (1)
Repositioning
Programmed
position n+1
Programmed
position n
Figure 5.
Position where
the robot stopped
Programmed
position n+2
Repositioning and recycling after manual jogging
The behavior of the active outputs and monitoring functions will differ according
to the procedure (repositioning or recycling) used when resuming work. These are
documented in the Operating Principles detailed in this User Manual.
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2 Welcome
2.4.3 Commands and events

Description
The synchronization with the cell environment is made through digital
inputs/outputs that are exchanged with the PLC and referred to as commands and
events .
The commands are information signals sent by the robot to the environment. The
events are information signals expected by the robot from the environment.
The commands and events can be programmed on positions when creating or
modifying paths. Appropriate instructions enable them to be programmed either a
fine point or on a fly-by point.
Commands
Line or Cell
PLC
Robot
Controller
Events
Figure 6.
Commands and events
2.4.4 Tooling commands and events

Description
The synchronization with a tooling controller is made through digital
inputs/outputs that are exchanged with the tooling controller and referred to as
tooling commands and events .
The tooling commands are information signals sent by the robot to the tool
cabinet. The tooling events are information signals expected by the robot from
the tool cabinet.
The tool commands and events can be programmed on positions when creating or
modifying paths. Appropriate instructions enable them to be programmed either a
fine point or on a fly-by point.
Tooling Commands
Tool Control
Cabinet
Robot
Controller
Tooling Events
Figure 7.
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Tooling commands and events
21
2 Welcome
2.4.5 Material handling management

Overview
The clamping components, whether these are fixed or integrated in a gripper, are
made of monostable or bistable actuators, associated with sensors used to check
their position. The actions on these components are referred to as Handling
sequences , or "Gripper actions".
Some sensors are also used to detect the part picked up in the gripper. These
signals are referred to as Part detection signals.
Note: The handling sequences can also be used to control other components than
the grippers. These are used for example to manage the tip extractors and the tip
dresser flaps operated by the Spot Welding process.
Depending on the complexity of the site, the handling sequences and the part
detection sensors can be managed either by the robot or by the PLC. The two
management modes can be used together (example: material handling managed by
the PLC, but tip dresser flaps managed by robot sequences).
Material Handling managed by PLC
In this configuration, the PLC manages the actuators and monitors the sensors.
Programming in the robot paths is done through specific PLC commands and
events.
The management of the part sensors is in this mode entirely unknown from
Promia. If so defined by the integrator, the handling sequences managed by the
PLC can be controlled manually on the robot teach pendant when the robot is not
executing any motion program.
Material Handling managed by robot
The handling functions of the basic application can process up to 16 sequences
(pneumatic actuators, suction cups ) using digital inputs/outputs for which the
programming is entirely open to the integrator. Each time a sequence is controlled,
correct operation of the sequence is verified by checking and monitoring the
feedback inputs related to the programmed action.
These sequences are typically programmed on fine points. Execution of a
sequence then incorporates both the control and check actions. It is also possible
to initiate control actions on a fly-by point and perform the associated checks on
the following fine point.
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2 Welcome
2.4.6 Debug mode

Definition
The debug mode is used to test the robot programs, without a part, when the
installation is not yet complete.
This mode can be activated both in manual mode and in automatic mode and is
used, among others, to verify the program structure, the accessibilities and the
movements of the cables.
This mode is activated by a specific input, DEVERM, included in the table of
exchanges with the PLC.
In the mode:
the processes are inactive,
if material handling is managed by the robot, the part detection functions

are replaced by wait times. The values of these times can be configured
by the integrator,
if handling is managed by the robot, the handling sequence checks can

be activated or inhibited in accordance with a specific configuration for
each sequence. If inhibited, they are replaced by wait times. The values
of these times can be configured by the integrator.
The transition from debug mode to real mode is immediate for the handling
sequences and part detection functions. Reactivating the process is generally
performed when the next program code is received.
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2 Welcome
24
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3.1 General information

3.1
General information
Section content
This section describes the architecture of the application software, the organization
of the RAPID files and the organization of the memory.
3.2
Loading the application software
ABB supply
The robot controller supplied by ABB contains the pre-installed Promia
application software.
Reinstallation of the application software is described in the Promia integration
guide.
P-Start
When a user module common to several tasks has been modified, the application
software must be reinitialized by a P-Start command.
In the
ABB menu, select "Restart"
Select "Advanced"
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3.2 Loading the application software
Tap P-Start and validate by OK
Initiate by P-Start
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3.3 Software architecture
3.3
Software architecture
Composition of the controller software

Once the Promia application has been installed, the software in the robot controller
has the following architecture:
Trajectories
Integrator Process
Modules
Integrator Common Base Modules
Promia Process Modules
Promia Common Base Modules
ProcessWare
BaseWare
ABB RobotWare
PROMIA internal software (cannot be modified)
PROMIA customization
Figure 8.
Software architecture
The Promia delivery is divided into two distinct parts:

The Promia internal application software, ensuring the functions
described in this manual. These modules cannot not be modified by the
customer or the system integrator,
A pre-configuration of the integrator modules, providing the necessary

openings for integrator customizations and some examples of this
customization.
The combination of RobotWare and PROMIA source code build up a reference,

resulting in a specific Promia version. Any change made to any of these 2
components will result in a new reference and a new Promia version.
RDNU0006 Revision F
27

3.4 Organization of memory
3.4
Organization of memory
Task implementation
Two tasks are implemented for each independent mechanical unit:
a foreground task, also called motion task, which contains the movement
programs
a background task, which handles the continuous monitoring functions
Each of these tasks contains specific modules and modules which are shared
between the 2 tasks.
The non-modifiable modules of the common base of Promia are the same for each
mechanical unit. The non-customizable process modules are only included in the
tasks related to the mechanical units which use this process.
The customizable modules of Promia are specific to each mechanical unit.
If we consider a system with 3 mechanical units (3 robots) with the first one using
a process 1 and the 2nd and 3rd tasks using a process 2, the configuration will be as
follows:
Mechanical Unit 1
Foreground Task
Background Task
Promia internal modules

Foreground
Common Base
Foreground+
Background
Common Base
Background
Common Base
Foreground
Process 1
Foreground+
Background
Process 1
Background
Process 1
Customized Modules for Mechanical Unit 1
28
Foreground
Common Base
Foreground+
Background
Common Base
Background
Common Base
Foreground
Process 1
Foreground+
Background
Process 1
Background
Process 1
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3.4 Organization of memory
Mechanical Unit 2
Foreground Task
Background Task

Foreground
Common Base
Foreground+
Background
Common Base
Background
Common Base
Foreground
Process 2
Foreground+
Background
Process 2
Background
Process 2

Foreground
Common Base
Foreground+
Background
Common Base
Background
Common Base
Foreground
Process 2
Foreground+
Background
Process 2
Background
Process 2
Mechanical Unit 3
Foreground Task
Background Task

Foreground
Common Base
Foreground+
Background
Common Base
Background
Common Base
Foreground
Process 2
Foreground+
Background
Process 2
Background
Process 2
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Foreground
Common Base
Foreground+
Background
Common Base
Background
Common Base
Foreground
Process 2
Foreground+
Background
Process 2
Background
Process 2
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3.5 Organization of RAPID files
3.5
Organization of RAPID files
Organization on the FlashDisk

The mass storage of a robot controller is a FlashDisk named hd0a.
Located in the root of the FlashDisk is the RobotWare directory corresponding to
the RobotWare versions installed, the APPL-PROMIA50.xxx directory containing
the internal modules of Promia, and the robot systems that have been created. Most
often, the flashdisk only contains one version of RobotWare, one version of
PROMIA and one robot system.
The modifiable modules of Promia are installed in SiteX sub-directories of the
current robot system.
hd0a/
RobotWare_x.yy.zzzz
APPL-PROMIA50.xx
Current robot System
Backup
home
Site x
Syspar
Figure 9.
Organization on the flashdisk
In a single robot system, there is only one site sub-directory, called Site.
In a multi-robot system, there is a site directory for each of the independent
mechanical units. These directories are then named Site1, for mechanical unit No.
1, Site2, for mechanical unit No. 2, and so on.
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3.6 Contents of the Site directories
3.6
Contents of the Site directories
The Site directories contain all the customizable modules of Promia for a given mechanical unit. Their
contents will vary according to the processes installed on the corresponding mechanical unit.
3.6.1 Common base modules

List of customizable modules
Module name
(single robot
environment)
Module name
(multi-robot
environment
mechanical unit n)
Main purpose of module
CEL_CONF.SYS
CEL_CONF.SYS
Definition of constants common to

the cell ; loaded in foreground and
background tasks
CEL_MENU.SYS
CEL_MENU.SYS
Definition of screen container

menus and operator panel buttons
(see section 5 Man-Machine
Interface).
Note : This module only appears on
the site directory related to
mechanical unit 1
DEF_SITn.SYS
Definition of the names used for

sequences,
part
detection,
commands and events ; these names
will be used in the PROMIA
screens ; loaded in foreground and
background tasks
MAN_CNFn.SYS
Definition of signals used for part

detection ; definition of handling
sequence control and monitoring
functions; loaded in foreground and
background tasks
PERSO_AVP.SYS
PERSO_AVn.SYS
Integrator customization on system

events; actions to be performed at
end of movements to the home and
safe positions; loaded in foreground
task only.
PERSO_ARP.SYS
PERSO_ARn.SYS
Integrator customizations related to

continuous monitoring; loaded in
background task only.
LOCALIZATION
.SYS
LOCALIZATION
.SYS
Not really a customization module:

Used to implement the English
version of the application. Also
contains the definition of the safe
and home positions
PRG_MVT.MOD
PRG_MVn.SYS
Definition of paths and

sequencing in programs.
DEF_SITE.SYS
MAN_CONF.SYS
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31
their

3.6 Contents of the Site directories
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4.1 General controls of the robot controller
4.1
General controls of the robot controller
Available control devices
FlexPendant
Main switch
Emergency Stop
Motors On light & button
Mode selector (Manual/Auto)
Figure 10.
Robot system control devices
Optionally, a Move to Safe luminous push button can be provided.

Dedicated keys on the FlexPendant
There are two groups of dedicated keys on the FlexPendant: a group of
programmable buttons and a group of Execution Control buttons.
Programmables
Keys
Start
Move backward
Move Foreward
Stop
Figure 11.
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Dedicated keys on the FlexPendant
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4.2 Main menu of FlexPendant
4.2
Main menu of FlexPendant
Accessing the main menu

The main menu of the FlexPendant is accessed by pressing the
located at the top left corner of the FlexPendant.
button
Contents of the main menu
Figure 12.
ABB basic menu
The main menu displays two columns:

The left hand column is aimed to programming and everyday operation,
The right hand column is more dedicated to configuration and

maintenance operations.
Windows accessed from the ABB main menu are described in the IRC5 product
documentation.
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4.3 Considerations related to single and multi-robot environments
4.3
Considerations related to single and multi-robot environments
Promia is an application software designed to operate in both single and multi-robot environments.
Some of the screen snapshot examples in this document are taken from a system
with three robots controlled by the same robot controller. However, the principles
described are also valid in a single-robot environment.
Single robot and multi-robot system
In a single robot environment, the robot controller controls a single mechanical
unit or a group of mechanical units that run simultaneously. There is only one
foreground robot task containing the movement instructions for the robot.
A multi-robot system enables one single robot controller to control several
mechanical units independently. Software options are used, among others, to
coordinate and synchronize the movements of the different mechanical units.
In a multi-robot environment, there is a movement task for each independent
mechanical unit. These tasks are, by default, called T_ROB1, T_ROB2,
T_ROBn for the robot arm type mechanical units and T_POS1, T_POS2, T_POSn
for the positioner type mechanical units.
For compatibility purposes, the movement task, in a single robot environment, is
also called T_ROB1.
These movement tasks have a name which begins by T_ .

These must not be confused with the path names which also
traditionally begin by T_ .
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Specific features of basic MMI in a multi-robot environment

The main changes in RobotWare man-machine interface, compared to a single
robot system are as follows:
There is a programming environment for each robot.
ABB
In the
menu, the choice of the Program Editor window must be
followed by the selection of the foreground task to be edited (this
selection window does not appear in a single-robot environment) :
Figure 13.
The Production window displays several vertical tabs; there is one tab
for each foreground task.
Figure 14.
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Choice of program to be edited
Production window in a single-robot environment
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Figure 15.
Production window in a multi-robot environment
During execution, the program pointer is reliably refreshed in the production

window. This is not always the case in the Program Editor windows.
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4.4 Running the program
4.4
Running the program
Running the program in manual mode

If at least one of the robots controlled by the robot controller is not at its safe or
home position, it will be necessary to initiate program execution in manual mode.
Set the mode selector to "Manual"
In the
menu, select the Production Window in the left part of
the menu. If the program pointer was previously reinitialized at the start
of the program, the window displayed is as follows :
ABB
Figure 16.
Program restarted at beginning (single or multi-robot)
If this is not the case, reinitialize the program using the PP to Main
command. This command reinitializes the program pointers of all the
foreground tasks and requests a confirmation :
Figure 17.
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Confirmation of PP to Main (single or multi-robot)
Press the FlexPendant enabling device to set "Motors On" on the

robot(s)
Start execution by pressing the
button.
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4.4 Running the program
Running program in automatic mode
If all the robots are at the safe or home position, the program can be initiated in
automatic mode:
After having repositioned, if necessary, the program pointers to the start

of the program, as above,
Set the mode selector to "Auto"
Acknowledge the warning message on the FlexPendant :
Figure 18.
Confirmation of automatic mode
Press the Motors On pushbutton. The indicator light comes on steady.
Start execution by pressing the
button.
If the robot controller is connected to a PLC, the Motors On and start of execution
can be initiated from the PLC; see next section.
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4.5 Production modes
4.5
Production modes
This section starts with a description of the production enabled and production disabled modes, and the
way the corresponding PLC information are managed. This is followed by a detailed description the start of
production and the end of production operations. Finally, this section explains the way program codes are
managed by the application.
4.5.1 "Production enabled" and "Production disabled" modes

Interface with the PLC and behavior of the robot controller
Via a digital input, ENPRO, the robot is informed by the PLC if it is integrated, or
not, in the production stream.
When set, this input informs the robot controller that it is in the "PRODUCTION
ENABLED" mode. When it is reset, the robot controller has to be in the
"PRODUCTION DISABLED" state.
The use of this function is optional and has to be defined in accordance with the
needs of your site. If the Production enabled /disabled feature is not used, the
ENPRO input must be declared as inverted in the I/O signal parameters.
In both modes, the robot controller handles the position synchronization
information (commands and events) which link the robot to its environment. On
the other hand, according to the current mode, the robot controller reacts in a
different way to remote commands and program codes sent by the PLC.
Behavior in production enabled mode
The local and remote commands (Motors On (DMSP), start cycle (DDCY), move
to safe, stop ) are active.
The movement programs generated by the external code management system are
executed.
The production startup program (T_MoveToHome path) is automatically selected
once the robot reaches the safe position.
Behavior in production disabled mode
Only the "move to safe" request is active. The remote commands (Motors On
(DMSP), start cycle (DDCY), Service request) are ignored.
The robot terminates the ongoing movement program, but does not read the
external or internal program code which may be present on dedicated inputs. This
will usually leave the robot at home position, unless a "move to safe" request is
issued.
Once at the safe position, there is no automatic selection of the production startup
program (T_MoveToHome path).
When the production disabled mode is detected by the robot (ENPRO input off),
the Production Disabled message is displayed in the Production screen of
the application.
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4.5.2 Active commands according to operation modes

Summary of the active commands according to the different operation modes
Command
Manual mode
Automatic
mode,
"production
disabled"
Motors On button on robot

cabinet
Inactive
Active
Active
Enabling device on
FlexPendant (motors on)
Active
Inactive
Inactive
Inactive
Inactive
Active
Active
Active
Active
Active
Active
Active
Inactive
Inactive
Active
the
Remote Motors On request

(DMSP)
Stop
command
FlexPendant (
Start
on
Remote
(DDCY)
the
button)
command
FlexPendant (
Automatic
mode,
"production
enabled"
on
the
button)
start
command
4.5.3 Move to Safe and Move to Home commands

Accessing the "Move to Safe" command
The "Move to Safe" command is used, as a general rule, to bring the robots to their
safe positions by pressing
the Move to Safe pushbutton on the front panel of the robot cabinet,
when this button exists,
the graphic button on the operator panel when this button does not
physically exist (see 5.5 Operator panel screen) :
The "Move to Safe" command can also be run through a specific program code
which can be sent by the PLC, like any other program code, to request the end of
production.
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Move to Safe at program startup

When starting up programs, from the beginning, after having chosen for example
"PP to Main" in the production window, the application software sends first all
the robots to their safe positions in order to initiate production under known
conditions, using the production startup program and the T_MoveToHome path.
The production startup program is automatically selected once all the controlled
robots are at their safe positions.
Behavior according to initial conditions
Depending on the position of the robots when running programs from their main
routine, there are two possible situations:
If the robot is already at its safe position, the "Move to Safe" phase is
unnecessary and the robot waits there until the other robots have reached
their own safe positions.
If the robot is not at its safe position, a message on the Production

screen of the application informs the operator that he must press the
"Safe" pushbutton to initiate a movement to the safe position:
Figure 19.
Return to safe position prompt (single robot example)
The operator has to order the movement to safe position (no other command is
active). Depending on the hardware configuration, he can use either the Safe
pushbutton on the controller or the dedicated button on the Operator Panel
screen.
There are here 2 possibilities:
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Either the robot is at its home position; in this case, the movement to the
safe position is performed by the T_MoveToSafe path routine. This
movement to the safe position can be executed in automatic mode
provided all the robots are either at their home or at their safe position.
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The robot is not at its home position and not at its safe position (position
is considered as unknown). The movement to the safe position will run
the T_MoveDirectToSafe path and must then be performed in
manual mode.
If necessary, a message in the production screen will request the operator
to switch to manual mode; when this is done, the application displays a
direct "move to safe" dialog. This dialog must be acknowledged for each
robot requiring a direct movement to its safe position.
Figure 20.
Figure 21.
Switch to manual mode to initiate direct move to safe operation.
Direct move to safe dialog to be acknowledged for robots 1 and 2.
When the robot controller is equipped with a lighted "safe" pushbutton, the
indicator light flashes until all the controlled robots have reached their safe
positions. The "safe" indicator light on the virtual operator panel (see 5.5 Operator
panel screen) acts in the same way.
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Execution of production startup program

When all the robots controlled by the robot controller have reached their safe
positions, the production startup internal program is automatically selected and
will run the T_MoveToHome path.
Execution of this program requires either an operator acknowledgement, or a
remote validation from the PLC (through DDCY).
Figure 22.
Prompt: OK to Move to Home ?
In a multi-robot system, all the T_MoveToHome paths are generally

synchronized.
At the end of this path, the application is ready to accept any kind of program code
requests.
End of production
The end of production is achieved by generating a Move to Safe command. This
command can be generated locally using the safe pushbutton (either physical or
virtual), or remotely, by the Safe program code sent by the PLC.
When an end of production is requested locally, it is stored. The controlled robots
complete their ongoing work program and will continue by running the
T_MoveToSafe path routine. As long as all the robots have not completed their
current work program, a new action on the local safe button or on the dedicated
screen button will cancel the end of production request.
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When the robot controller is equipped with a lighted Safe pushbutton, the indicator
light flashes until all the robots have reached their safe position, or until the end of
production request has been cancelled. The safe indicator light on the virtual
operator panel (see 5.5 Operator panel screen) acts in the same way.
4.5.4 Catching and priority of program codes
Program code types

The program codes management consists in selecting the work to be executed by
the robot(s) in accordance with the state of the machine and the state of the robot
environment.
This selection can be made in two ways:
By an external system, generally a line or cell PLC which generates "an

external code" information transmitted to the robot controller according
to a predefined protocol.
By an internal function which generates the program code according

to information related to the process or to external information related to
the robot environment. This involves the following codes:
Move to safe commands,
service routines requested by the process
internal codes managed by the robot program
Catching of program codes

The program codes are caught at the end of the preceding program. Though reset
of the preceding external code may have been anticipated, the external code is only
read at this moment.
If several work requests occur simultaneously, the choice is made in accordance
with the priority algorithm defined below.
Reading of the program code can sometimes be inhibited. This is the case when
the system has gone into production disabled mode. This is also the case when
the process has been temporarily deactivated. The deactivation is used to terminate
a part which may have presented a problem, but does not allow any execution of
new parts. The process must therefore be reactivated in order to allow catching of
new program codes.
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Program code priority

The program codes are managed in accordance with the following priority levels
(indicated in decreasing order of priority):
(1)
(2)
(3)
(4)
Move to Safe command

Internal codes
Service requests.
External codes.
Fore more information on program code management, refer to the PROMIA

integration guide.
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4.6 Principles relative to actions and checks attached to a position
4.6
Principles relative to actions and checks attached to a position
Actions attached to a point and actions in movement

Unless explicitly specified, most of the actions programmable on path using
PROMIA are actions intended for programming on a fine point. We strongly
discourage using these actions on fly-by points as the moment and the location
when and where the action is actually performed are not predictable and may
therefore not be repeatable.
If programming on a fly-by point proves necessary to satisfy cycle time
requirements, specific actions, synchronized with the movement, should be used.
These actions are built using the MoveJ and MoveL instructions and contain the
parameters relative to the movement and the action to be performed, as well as
some synchronization parameters.
Information about expected feedbacks and errors
As a general rule, any moment the robot waits for a feedback signal on a
programmed position, a message is displayed on the TPU to inform the operator
and the reason why the robot is waiting is also sent to the PLC.
By default, no Stop is generated; the movements of the involved robot are
automatically stopped since execution of the program is blocked as long as the
information is not present. When the expected information appears, the program
resumes its normal sequence.
The PLC can however decide to generate a Stop via the robot controller
inputs/outputs. In this case, the error must be acknowledged on the PLC and
program execution must be restarted from the PLC.
The list of error messages is given in section 5.4 Error messages. The list of
corresponding codes sent to the PLC is given in the PROMIA integration guide.
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4.7 Continuous monitoring
4.7
Continuous monitoring
4.7.1 Dynamic monitoring

Description of dynamic monitoring
Some robot environment information items must be monitored continuously while
the robot is operating. This information can involve the cell environment or the
process (part detection or robot interlocking, for example).
This function is performed by the dynamic monitoring mechanism.
Whenever a monitored information item is missing, the robot is immediately
stopped on its path and an error message, sometimes time-delayed, is indicated on
the TPU and reported to the PLC. When the information reappears, the robot
automatically resumes its movement, without any operator action, unless the PLC
has forced a Stop and prompts for an error acknowledgement and a cycle start
action to restart execution.
This behavior may be disturbing for certain process phases and the dynamic
monitoring functions can therefore be enabled or disabled by programming during
execution of certain sections of a path.
Dynamic monitoring types
This mechanism performs continuous monitoring (between path points):
of the states of the part detection sensors,
of the states of the controlled handling sequence sensors,
of events.
Each of these functions can be monitored separately. When the production startup
program is executed, the states of the dynamic monitoring tasks take a default
value configured by the integrator.
In the basic configuration supplied by ABB, the dynamic monitoring relative to
part detection and the handling sequences are activated by default. The dynamic
monitoring tasks related to the events are disabled.
This configuration is located in the robot Def_site module:
!------------------------------------------! Flags d inhibition des contrles dynamiques
!------------------------------------------CONST bool Active_ctl_cpp:=TRUE;
!part detection
CONST bool Active_ctl_evo:=FALSE; !tooling events
CONST bool Active_ctl_ev:=FALSE;
!PLC events
CONST bool Active_ctl_seq:=TRUE;
!gripper actions
The integrator can modify this configuration of the default states. For each of the
variables, TRUE means enabled by default, and FALSE means disabled by default.
The state of the enabled monitoring tasks can be modified in the robot programs
using the MonitorInputs instruction.
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4.7 Continuous monitoring
4.7.2 Error management

Monitoring of ongoing errors
The application displays and erases messages during execution of the programs
and paths.
There are three types of messages:
information messages
simple error messages,
error messages requiring an operator acknowledgement.
Robot behavior
Display and erasure of these messages is monitored continuously:
The information messages have no effect on operation of the robot or the
cell.
When a simple error message or an error requiring acknowledgement

appears, execution of robot movements is blocked, and remains blocked
as long as the message is displayed.
Once the condition which has generated the error disappears :
the simple error message is erased and execution of the robot

movement resumes without any operator action.
the fault message with validation disappears and a screen

requesting operator validation is displayed. Execution of the
robot movement will only resume after the message has been
validated.
About the Man-Machine Interface relative to errors, see 5.3 Production.

Be attentive to a program sequence of the following type:
1/ Display of an error message other than an information message
2/ Robot movement
3/ Erase the message
The robot movement will be blocked since an error message is displayed. This
blocked condition will only end when the message has been erased, and therefore
after the end of the movement which will never take place A program
sequence of this type will therefore lead to complete blockage of the robot.
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4.8 Behaviors in cases of exception
4.8
Behaviors in cases of exception
The behavior of the application software will vary according to the complexity of the exception. On a simple
exception, such as a stop or an emergency stop, followed by a restart with no jogging or modification, the
application software does not take any special action.
On the other hand, when restarting after manual jogging or modification of the program pointer, the behavior
will be very different depending on how the work will be resumed: repositioning or recycling. For the
meaning of these terms, refer to 2.4.2 Repositioning and recycling principles.
4.8.1 Behavior during manual jogging

Inhibition of the monitoring functions
During a robot stop followed by a transition to manual mode, manual jogging of
the robot will never be blocked by any check made by the application (either the
check is performed on position or from continuous monitoring).
If sequences are manually controlled, they are monitored, but only to display
possible feedback errors in the dedicated handling sequence screen.
4.8.2 Behavior in case of repositioning

During repositioning
While the robot regains its path, the behavior is similar to the one during manual
jogging: no check will block the repositioning operation and, if any sequences are
controlled, they are monitored, but only for the purpose of displaying possible
errors.
At end of repositioning
At the end of the regain operation, the dynamic monitoring tasks are restarted in
the same condition as they were prior to the exception, and any active checks made
on position are reinitiated.
The sequences are monitored in accordance with the control state programmed in
the paths.
4.8.3 Behavior in case of recycling

Re-initialization of checks
When recycling starts, the monitoring tasks are reinitialized as follows:
The dynamic monitoring tasks return to their default state, as defined by
the integrator
The part detection information is reinitialized to the unknown (idle) state
The events are reinitialized to an unknown (idle) state
The sequences are monitored in accordance with their current control

state (programmed or manually controlled).
The recycling movement is run at low speed.
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5.1 General description of the screen container
ABB
The screens of the Promia application software are not initiated from the
menu, but from a tab in the
task bar, known as the Screen Container, which is always visible. The container starts up automatically at
controller startup.
5.1
General description of the screen container
General aspect
The container gives access to the application screens through a floating panel,
located by default at the top right corner of the screen.
Figure 23.
Screen container and floating panel
Floating panel
The floating panel can be moved from top to bottom and from bottom to top to
allow reading the screens which it covers with no interference.
It comprises three elements:
The right hand part acts as a handle to move the floating panel :
Figure 24.
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Floating panel control handle
51
5.1 General description of the screen container
The top button, to the left, displays a blue command bar used to select
the screen of the application software to be displayed.
Figure 25.
Application software screen selection button
The lower button, to the left, is used to toggle between the current screen
and the Operator Panel screen ; it is thus possible, using this button,
to call up, at any time, the Operator Panel screen which contains a
virtual button set used to request "Move to Safe position" or for
service requests:
Figure 26.
Button used to toggle between current screen and Operator Panel

screen.
Selecting a screen
When the screen selection button is pressed, a blue command bar appears (over the
current command, if one is displayed):
Figure 27.
Application software screen selection command bar
The selection button aspect changes; when the button is pressed again, the blue
command bar disappears.
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5.2 Choice of "Common Features" screens
5.2
Choice of "Common Features" screens

The elements displayed in this blue command bar depend on the processes
managed by the application software, especially in a multi-robot environment,
where several processes are implemented.
The command bar always contains however a first item used to select the screens
of the common base application, and is referred to as the Common Features.
This menu has three sub-menus which gives access respectively to the production
screen, the information screens common to all the processes, and to a simplified
backup screen:
Figure 28.
Selection of "Common Features" screens
These screens are described in the following sub-sections of this section.
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5.3 Production screen
5.3
Production screen
The two areas of the production screen

This screen contains a command bar and a display with two separate areas:
the upper half, called the Program area, displays the state of the current
programs and paths,
the lower half, called the Message area, displays the application software
messages.
Program area
Messages area
Command bar
Figure 29.
The two areas of the Production screen
The command bar is used to control the display in the Messages area; it is
described in the corresponding section.
5.3.1 Program area details

The 12 fields of the program area
Each line of the program area has two fields.
The first line indicates the version of the application software installed and the
processes controlled by the various robots of the cabinet. In the example below,
robot 1 is a handling robot and robots 2 and 3 are arc welding robots:
The second line displays the external code present on the inputs of the robot
controller, "xCode" and the program codes currently accepted by the application
software
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In the example above, no external code is present and the codes executed by the
application are a normal "Move to Safe", performed from home position, for robot
1, and a direct move to Safe for robots 2 and 3.
Lines 3 to 6 contain, for each of the robots (4 maximum), the names of the current
programs and paths, as defined by the integrator; see instructions
DisplayProgram and DisplayPath in section 7.2 Giving information
about active path and active robot program.
5.3.2 Message area details

The Message Area has two operating modes: a "snapshot" mode and a "history" mode. The two modes are
controlled from the command bar of the production screen.
Figure 30.
Example of snapshot message area
Description of command bar

The command bar contains 3 icons used to control the display in the Message area:
is used to display, in the Message Area, a snapshot of the

messages, whatever their type is. This is the default mode.
is used to display a history of error messages
is used in both modes to force refreshing of the messages,.
The active display mode is indicated in the corresponding icon as a tick symbol:
56
The
icon indicates that the current display mode is the
snapshot mode,
the
icon indicates that the current mode is the history mode.
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Figure 31.
Example of history area messages
Content of Message area

The Message area contains an instant view or a history of the application software
messages.
The messages are time-stamped and the order of appearance of the messages is
preserved.
button can be used to reverse the order of the messages.
The
Format of messages
All the messages displayed have a common format:

an icon specifying the type of message
for an information message
for a simple error message
for an error message requiring validation
The time at which the message has appeared
The robot (movement task) at the source of the message
The text of the message itself; these texts, their meaning and the actions
to be performed are detailed in the next section.
The movement tasks have a name which begins by T_ . This must not be
confused with the path names which also traditionally begin by T_
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Validation of messages
A message validation request is only displayed when the cause of the error has
disappeared.
A dialog comes up in the foreground of the screen container:
The movements of the robot(s) only resume after this dialog has been
acknowledged by the operator.
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5.4 Error messages
5.4
Error messages
The error messages are presented here according to their source (common base or process), then according to
their seriousness.
5.4.1 Common base application messages

List of errors requiring a validation
Type of
message
Wording
Description
Source/Cause: Air detection signal (CPAIR)
went low.
TCV1: AIR CHECK

ERROR
TCV2:
PROGRAM
DOES NOT EXIST
Check/Correction: Check if the air is

effectively cut off; if so, check the compressed
air circuit; if not, check the sensor and wiring.
Source/Cause: Program code received does not
match any valid program number.
Check/Correction: Check external
received. Check your program.
code
List of simple errors

Type of
message
Wording
Description
Source/Cause: Robot
information went low.
TCS1: WAITING
FOR MOVE ENABLE
TCS2: NO
COMMUNICATION
WITH PLC
TCS3: COOLING
DEVICE ERROR
movement
enable
Check/Correction: Check input signal AEVRB.

If input is used, check for possible causes of
robot movement inhibition on the PLC.
Source/Cause: PLC network failure
Check/Correction : Check network link to the
PLC
Source/Cause : air
information went low.
cooler
operating
Check/Correction : Check input di_ClimOk
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5.4 Error messages
Type of
message
Text
SQS1: GRIPPER
FEEDBACK LOST : n
Description
Source/Cause: Dynamic check of sequences is
active and at least one sensor for the specified
sequence is not in its state expected
Check/Correction: Check state of sensors and
actuators for the specified sequence
Source/Cause: Use of an undefined sequence
(not defined in MAN_CONF module)
SQS2: UNDEFINED
GRIPPER ACTION: n
CPS1: PART
DETECTION LOST:
n
Check/Correction: Use another sequence or

configure the corresponding actions and checks
in MAN_CONF module
Source/Cause: Dynamic monitoring of part
detection sensors is active and the specified
part detector is not in its expected state.
Check/Correction: Check state of part detection
sensors in corresponding Promia screen
Source/Cause: Dynamic check of events is
active and specified monitored event has
disappeared.
EVS1:
PLC
EVENT LOST : n
Check/Correction: Check state of events in

Promia screen. Check link with PLC (if parallel
link).
On the PLC, check conditions which may cause
the loss of this event.
Source/Cause : Robot movement stopped since
specified event is not present at the end of a
MovePlcEvent instruction
EVS2: NO PLC
EVENT WHILE
MOVING : n
Check/Correction: Check state of events in

corresponding Promia screen .
Check link with PLC (if parallel link).
On the PLC, check conditions which may have
caused this event not to be sent.
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5.4 Error messages
List of information messages
Type of
message
Text
Description
Source/Cause: All robot programs have been
stopped
TCM1: ALL ROBOT

PROGRAMS
STOPPED!
Check/Correction: A Stop command, local or

remote, has been generated.
Also check, in ABB production window, if a
Stop instruction has been programmed.
TCM2: PLEASE
PRESS SAFE PUSH
BUTTON
Source/Cause: After PP -> Main, robot is not at

its safe position.
Check/Correction: Order the return to the safe
position by dedicated pushbutton (physical or
virtual)
Source/Cause: Debug mode has been selected
through "DEVERM" input signal.
TCM4:
MODE
DEBUG
Check/Correction: None.
(information message)
Source/Cause: Odd parity check (CPCO signal)
is not consistent with the external code group
signal (odd number of bits being set).
TCM5:
ERROR
PARITY
Check/Correction: Check interface with PLC.

Example of parity errors:
code =1 and CPC0=1 + CVC1=1
code =3 and CPC0=0 + CVC1=1
Source/Cause: If external code is used: code
reset has been correctly performed, but the
external code group signal is 0.
TCM6: WAITING
FOR CYCLE CODE
(simple information)
Possibly check interface with PLC.
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5.4 Error messages
Type of
message
Text
TCM7: WAITING
FOR CYCLE CODE
RESET
Description
Source/Cause : Wait for cycle code reset, that is
transition to 0 of code signal, code validation
signal, odd parity signal, and transition to 1 of
CVC_0 signal (pulsed)
Source/Cause: Robot motors are off.
TCM8: PLEASE
SWITCH MOTORS
ON
TCM9:
PRODUCTION
DISABLED
Source/Cause: ENPRO signal is 0 (if function

is used in application).
Source/Cause:
repositioning.
TCM12: REGAIN
REQUESTED PRESS START
Transient
message
during
(simple information ; restart request is also
generated by basic software)
TCM14: WAITING
FOR EVENTS TO
SWITCH FROM
Source/Cause: Message to be used at start of a

part program when the executed path has to be
selected according to two different events and
none of them is received.
Check conditions preventing PLC from sending
one of the two events.
Source/Cause: Robot currently moving to its
safe position.
TCM15 : MOVING
TO SAFE POSITION
TCM16: MOVING
TO HOME
POSITION
Source/Cause: Robot currently moving from its

safe position to its home position.
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5.4 Error messages
Type of
message
Text
TCM18: RELEASE
CYCLE START PB
Description
Source/Cause: Remote cycle start information
(DDCY) still present when program resumes
execution.
Source/Cause: Speed is limited since program
is recycling.
TCM20: RECYCLING
SPEED<=250MM/S:
TCM21: MOVE TO
SAFE ONLY FROM
HOME
TCM22: SERVICE
ROUTINE ONLY
FROM HOME
TCM23: SWITCH TO
MANUAL MODE
AND START
Source/Cause: Move to safe request (during

production) is rejected since all the robots are
not at their home position.
Check/Correction: Execute a program which
ends at home position and repeat the Move to
safe request.
Source/Cause: Service request rejected since all
the robots are not at their home position.
Check/Correction: Execute a program which
ends at home position and repeat the service
request.
Source/Cause: Robot is not at its safe position,
and not at its home position. Moving to the safe
position will be a straight movement that can
only be executed in manual mode.
Check/Correction: Switch to manual mode,
press the enabling device and reinitiate
execution by
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button.
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5.4 Error messages
Type of
message
Text
TCM24: RESTART
IMPOSSIBLE =>
STOP/START
Description
Source/Cause: Robot is too far from the
location where its movement has been
stopped (by a dynamic check)
Check/Correction: Stop execution by
and
restart by
SQM1: WAITING
FOR GRIPPER
ACTION : n
Source/Cause: Robot is waiting for gripper

sensor signals to be in accordance with the
programmed gripper command (check on
position).
Check/Correction :
actuators
SQM2: (INFO)
GRIPPER FEEDBACK
LOST : n
CPM1: WAITING FOR

PART DETECTION: n
Check
sensors
and
Source/Cause: Robot has lost a gripper sensor

info during a direct move to safe position, or
after a start from a routine (pp->routine).
Check/Correction: None; but note that if this
problem persists when reaching the safe
position, this will become a blocking
condition.
Source/Cause: Specified part detection signal
is different from what is expected (check on
position).
Check/Correction: Check part detection
sensors in the corresponding Promia screen.
Source/Cause: Specified expected event is not
present (check on position).
EVM1: WAITING
FOR PLC EVENT : n
Check/Correction:
Check
corresponding Promia screen.
events
in
Check link with PLC (if parallel link).

On the PLC, check conditions which may
have caused this event not to be sent.
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5.5 Operator panel screen
5.5
Operator panel screen
This screen replaces a set of physical buttons and lamps; it includes, by default, a lighted safe pushbutton
and 4service pushbuttons. These 4 buttons are used to request the corresponding service routines.
The operator panel screen can be customized in accordance with the installed processes.
Access
This screen is accessed using the key at the bottom left of the floating panel of the
screen container:
Default content of screen
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5.6 Promia information screens
5.6
Promia information screens
This set of screens supplies information related to the application functions that are common to all the
processes.
Access to common information
These screens are accessed from the blue command bar which is called up by
pressing the button at the top left of the floating panel of the screen container, and
then through the Common Features Menu:
5.6.1 General description of the information screen

5 parts of screen
The Promia information screen is made of 5 parts:
tabs used to choose the mechanical unit for which the information will
be displayed
66
a title showing the title of the current screen
a line displaying additional information or the instructions to perform an

operation,
the page displaying the information,
the menu area used to select the type of information to be displayed.
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tab to select
mechanical unit
Screen title
Additionnal
information or
instruction
Page,
information displayed
Menu,
screen selection
Figure 32.
Structure of Promia information screens
Information displayed
5 different types of information can be displayed. Each type of information is
displayed in a screen.
Screens are selected from the Menu area.
The first two screens are related to the handling functions and respectively display
the part detection and sequence states.
The following two screens are related to dialogue with the PLC or with the tool
control cabinet and respectively display the PLC or tool event and command
states.
The 5th screen displays the execution context and, especially, the state of the
active dynamic monitoring functions.
Persistence of type of information displayed
Accessing from the Common Features screen selection menu always calls up the
first screen (part detection).
The change of screen is performed from the Menu area.
The change of mechanical unit using the Tabs area preserves the current type
of information and therefore the current screen; only the contents of the page is
changed to reflect the information related to the selected mechanical unit.
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General remark concerning names displayed in these pages
The names displayed in these pages are read from the DEF_SITn modules as
entered by the integrator.
These modules are supplied by ABB with default names which are not necessarily
relevant for a given site.
The relevance of the display names is therefore strictly dependent on the
customization defined by the integrator.
5.6.2 Part detection screen

Content of pages
The part detection screen includes only one page displaying the expected state of
the 8 part detection sensors available for a mechanical unit.
Each part detection sensor is represented by its name and a pictogram indicating
the compliance of its actual state with respect to its expected state.
If no name has been defined for a part detection sensor, the corresponding fields
remain empty. In the examples below, only part detection sensor 1 name has been
filled in.
By default, following re-initialization of the corresponding robot program, or after
execution of a CheckPart instruction without any argument, the part detection
sensors are in an undefined state: their expected state is unknown and their actual
state is not tested. Under these conditions, no compliance information is displayed:
Figure 33.
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Part detection screen : undefined state
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When a CheckPart instruction is executed, the expected state of the part
detection sensors involved by this instruction is known. A pictogram is displayed
to the left of their names to indicate compliance (green colour) or non-compliance
(red colour) of the actual signal compared with its expected state.
Example 1: Part detector 1 expected to be 1 and actual state is correct
Figure 34.
Part detection screen : correct state
Example 2: Part detector 1 expected to be and actual state is incorrect
Figure 35.
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Part detection screen : wrong state
69
5.6.3 Sequence screen

Content of pages
The sequence screen includes two pages:
a page displaying the general state of the sequences and used to select a
sequence,
Figure 36.
A page displaying the detailed state of the selected sequence and used to
control it.
Figure 37.
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Page showing general state of sequences
Page showing detailed state of a sequence
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General state of sequences
Each sequence is represented by its name, its programmed state (state requested by
program during execution), its actual state (state currently controlled) and by a
pictogram indicating compliance of its actual state with respect to its expected
state.
By default, following re-initialization of the corresponding robot program (PStart), the sequences are in an undefined state: their controlled state is unknown
and the sensors are not monitored. Under these conditions, no compliance
information is displayed:
Figure 38.
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General state of Sequences : undefined state
71
Once the movement program is reinitialized (pp->Main, Exec), the control state of
the sequences which have been used in the program is displayed and monitored by
the application software. The pictograms indicating the state of the sequences are
refreshed.
The Programmed State and Actual state fields of the defined sequences, but
which are not used on the path, remain empty.
Example1: Sequences 1 activated and monitored OK:
Figure 39.
Sequence Screen : correct state
Example2: Sequence 2 activated and monitored NOK:
Figure 40.
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Sequence Screen : feedback error
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Details and control of sequences
To select a sequence to be zoomed-in or controlled, the operator simply taps
two times on the corresponding line. The first tap shows the selected line
highlighted:
The second tap on the line opens the detail screen showing the state of the sensors
related to the sequence and identifies, if relevant, the faulty sensor.
Figure 41.
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Detail screen of sequences, manual control not enabled
73
For each sensor, the screen displays its name, its expected status and, in real time,
its physical state. It also displays the control state of the actuators controlled by the
selected sequence.
The Sequence details screen includes a specific command bar used for manual
control of the sequence: the first two selections are used respectively to activate
and deactivate the sequence. Their wordings correspond to those entered in by the
integrator for this sequence.
These controls are greyed in (see figure above) when manual control of the
sequence is not enabled (individual inhibition of this sequence, program execution
in progress, automatic operating mode, motors off or enabling device released).
Note: In this screen, it is possible to manually control all the sequences defined,
whether they are declared, or not, as usable in the path. You may, for instance,
control a sequence trhat is managed by the PLC.
When manual control of the sequence is possible (program stopped, manual mode,
motors powered up, enabling device pressed, no specific inhibition for this
sequence), the control keys become active:
Figure 42.
Sequence detail screen, manual control enabled
The current control state is indicated at the top right of the screen. The state of the
sensors is refreshed in real time, even if the enabling device is released.
CAUTION: Controlling a sequence can have dangerous consequences on the

environment: dropping the part, initiation of the movement of a large actuator
(dressing flaps, for example).
Before controlling the sequence, make sure the operation is safe for personnel and
equipment.
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Select Close to return to the general sequence screen.
Any possible inconsistency between the programmed state and the state actually
controlled is displayed as a warning:
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75
5.6.4
PLC and Tool Event Screens
Content of pages
The events screen includes two pages respectively displaying the state of the 16
PLC events and the 16 tool events related to the selected mechanical unit.
The choice between PLC events and tool events is made in the Events
sub-menu:
The two pages are similar. Only the screen title is different. Each event is
represented by its number and its name:
Figure 43.
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Events screen : Correct state
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Only the events which are expected and not present, either in a path action, or in
the dynamic monitoring, are indicated by an error pictogram:
Figure 44.
Events screen : error state
In the example above, event 1 is expected but missing.
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5.6.5 PLC and Tool Command Screens

Content of pages
The Commands screen includes two pages respectively displaying the states of the
16 PLC commands and the 16 tool commands related to the selected mechanical
unit.
The choice between PLC commands and tool commands is made in the
Commands sub-menu.
The two pages are similar. Only the screen title is different. Each command is
represented by its number, its name and a LED when the command is set:
Figure 45.
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PLC Command Screen
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5.7 Backup screen
5.7
Backup screen
This screen is used to perform a simplified backup of the complete application.

The backup is identical to the one performed in the standard ABB screen, but the backup paths are predefined
by the integrator for 3 types of media: flashdisk, USB port and network.
Caution: EACH NEW BACKUP ON A MEDIA OVERRIDES THE PREVIOUS BACKUP MADE ON THIS
MEDIA.
Note: These screens do not allow any access path modification. If the operator wishes to perform a backup out
of the predefined paths, he must use the standard backup procedure, accessible from the ABB menu.
Access
This screen is accessed from the blue command bar, which is displayed by
pressing the button at the top left of the floating panel of the screen container , and
then through the Common Features Menu:
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5.7 Backup screen
5.7.1 General description of screen

4 parts of the screen
This screen includes a menu bar used to select the media on which the backup will
be performed, a reminder of the action to be performed, a reminder of the path of
the directory on which the backup will be performed, and an action button to
initiate the backup operation.
Figure 46.
Simplified Backup screen.
The 3 pictograms on the command bar are used respectively to select the
FlashDisk, the USB port or a remote computer.
If not customized by the integrator, the application software creates backups in the
default directories for the FlashDisk (directory: REST_ABB) and the USB key
(BACKUP_, followed by current date, for example Backup_2007_04_06). If the
path for backup on a remote computer is not defined, the button in the
corresponding screen is greyed in and disabled.
80
).
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5.7 Backup screen
Summary:
Pictogram
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Media
Default directory
FlashDisk
/hd0a/systemName/REST_ABB
USB
/bd0/Backup_CurrentDate
Network
None
Corresponding
button
81
6 Editing paths
6 Editing paths
6.1
General information
The paths are edited using the "Program Editor" window.
Each path is a routine the name of which begins, as a standard practice, by the
characters T_. The standard program editing commands are available. The
specific instructions of the application software can be chosen directly for insertion
in the paths.
General procedure
ABB menu, select the "Program Editor" window.
In the
In a multi-robot environment, select the foreground task to be edited.
Select the module, then the routine to be edited.
Move to the line to be edited.
It is also possible to edit the program line currently executed from the Production
window. In this case, select Debug, then Edit Program:
Figure 47.
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Debug Menu of the Production Window
83
6 Editing paths
6.2 Insertion of a specific instruction of the application
6.2
Insertion of a specific instruction of the application
Access to specific instructions

The specific instructions of the application are located in the Most Common list 1
and 2 of the instruction panel that appears when using the Add Instruction
menu.
The PROMIA list contains the actions which are common to all the processes.
The PROCESS list gives access to the actions specific to the process.
Note:
When opening the program editor, a button is displayed in the task bar with the
name of the movement task and the name of the module currently being edited
(here, T_ROB1, PRG_MVT).
The movement tasks have a name which begins by T_ . Do not confuse this
with the paths names which also traditionally begin by T_
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6 Editing paths
6.3 Inserting a Common base instruction
6.3
Inserting a Common base instruction

The actions common to all the processes, also called common base actions are
displayed on 2 pages:
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85

7.1 Programming anti-loop functions

7.1
Programming anti-loop functions
Principles of anti-loop management

This function is used to prevent looped execution of a work path routine, in
automatic mode, after having set the execution cursor on the first line of this
routine (Menu: Debug Move PP to Routine of the Program Editor window, see
Figure 3 Debug menu).
This is achieved using two instructions, "EnablePath" and PreventLoop.
During execution of the PreventLoop instruction, operation is as follows:
If an EnablePath instruction has been executed previously, the

PreventLoop instruction has no effect.
Otherwise
If the routine is executed in automatic mode, a message "LOOP ON

PATH FORBIDDEN IN AUTO MODE!" is displayed. After the
message has been acknowledged, the program is restarted from the
main routine.
If the sequence is executed in manual mode, a message: "Beware:

Starting Trajectory" is displayed and the application software prompts
the operator to validate or abort execution. If the message is validated,
the path is executed. If the operator chooses to abort, the program is
restarted from the main routine.
These dialogs are displayed in the operator window:
Figure 48.
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Acknowledgement of anti-loop message
87

7.1 Programming anti-loop functions
Example of path call:
PROC Programme(
num prog)
TEST prog
CASE 1:
DisplayProgram prog,"Prog 1";
! pulse code acknowledge signal
PulseDO\PLength:=1,ACQ_CODE1;
EnablePath;
Traj1;
.
Example of path:
PROC Traj1()
DisplayPath "Traj 1";
PreventLoop;
MoveL *,
.
MoveJ *,
ENDPROC
Figure 49.
Calling a path
Programming an EnablePath instruction
Syntax:
EnablePath
No parameter
Programming a PreventLoop instruction
Syntax:
PreventLoop
No parameter
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7.2 Giving information about active path and active robot program
7.2
Giving information about active path and active robot program
How to display current program and path

In order to display the names of the current robot programs and paths, this
information must be given at the right moment.
The current robot program name is typically given using the DisplayProgram
instruction in the corresponding CASE to the Programme routine.
The current path name is typically given through a DisplayPath instruction at
the beginning of the routine dedicated to this path.
Example: see Figure 49: Calling a path.
Programming a "DisplayPath" instruction
Syntax:
DisplayPath
pathName
Mandatory parameter
Name :
Meaning :
pathName
Name of path currently being executed
Programming a "DisplayProgram" instruction

Syntax:
DisplayProgram
programNumber
programName
Mandatory parameters
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Name :
Meaning :
programNumber
Number of the robot program currently being executed
programName
Name of the robot program currently being executed
89

7.3 Programming PLC commands
7.3
Programming PLC commands
Command management principles

PLC commands are information signals sent by the robot to its environment (via a
PLC). This logic information can be programmed on positions when creating or
modifying paths.
The PLC commands are only sent during program execution. They are generated
when a SendPlc action is programmed on a fine point or a MoveSendPlc
instruction is programmed on a fly-by point:
The commands are reset during path teaching, in case of recycling, when
a movement program is aborted or after having moved the robot to its
safe position.
The commands are programmed by blocks of 16. The commands not

programmed in one instruction are reset. You must the re-program on an
instruction all the commands previously set that you want to remain set.
7.3.1 SendPlc instruction

Purpose and operation
This path instruction entitles you to send up to 16 PLC commands on the same
position.
Generation of the commands may be delayed by using an optional argument
\Delay. This parameter defines the value of the delay in seconds. If this argument
is used, generation of all the programmed commands is delayed.
Example:
SendPlc \O1;
Programming a SendPlc instruction
Syntax:
SendPlc
[\Delay][\O1][\O2][\O3][\O4][\O5][\O6][\O7][\O8]
[\O9][\O10][\O11][\O12][\O13][\O14][\O15][\O16]
Optional parameters:
90
Name :
Meaning :
\Delay
Command generation delay, in seconds
\O1 ... \O16
Specifies that the corresponding command (1 to 16) must be

set.
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7.3 Programming PLC commands
7.3.2 MoveSendPlc instruction

Purpose and generation
Generation of commands can also be programmed using the MoveSendPlc
movement instruction.
This instruction is used to generate commands in the fly-by area, but cannot be
used to delay generation of the commands.
Example:
MoveSendPlc \L,*\O1,v1000,z20,tool0,wobj0;
Programming a MoveSendPlc instruction
Syntax:
MoveSendPlc
[\L] ToPoint [\Id] [\O1][\O2][\O3][\O4][\O5][\O6]
[\O7][\O8][\O9][\O10][\O11][\O12][\O13][\O14]
[\O15][\O16] speed zone tool wobj
Mandatory parameters :
Name :
Meaning :
ToPoint
Position, target of the movement, where the programmed

commands will be sent
speed
Programmed speed for the movement
zone
Definition of fly-by zone
tool
Reference of tool used for movement
wobj
Reference of object used for movement
Optional parameters :
Name :
\L
Meaning :
Defines the type of the movement as linear.
(by default, the movement is a joint movement)
\Id
Synchronization identifier for use in synchronous movement
\O1 ... \O16

set.
The position is stored when creating the instruction and can subsequently be
modified using the Modify Position command of the program editing window.
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91

7.4 Programming events
7.4
Programming events
Event management principles

Events are information expected by the robot from its environment. This logic
information can be programmed on positions when creating or modifying paths.
The events are only expected during program execution. They are expected as
soon as a PlcEvent action is programmed on a fine point, or a
MovePlcEvent instruction is programmed on a fly-by point:
The events are not expected during path teaching.
Cancelling a movement program aborts the wait for programmed events.
The events can be monitored dynamically. In this case, the last expected
programmed state is the one which is dynamically monitored.
By default, the dynamic monitoring on the events is inactive.
Only the events programmed in one instruction are expected. To check

that previously received events are still present, you must program them
again in further instructions.
7.4.1 PlcEvent instruction

This path instruction entitles you to wait for up to 16 PLC events on the same
position.
Example:
PlcEvent \E1;
Programming a PlcEvent instruction

Syntax:
PlcEvent
[\E1][\E2][\E3][\E4][\E5][\E6][\E7][\E8]
[\E9][\E10][\E11][\E12][\E13][\E14][\E15][\E16]
92
Name :
Meaning :
\E1 ... \E16
Specifies that the corresponding event (1 to 16) is expected

to be set.
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7.4 Programming events
7.4.2
MovePlcEvent instruction

The test of events can also be programmed in the fly-by point area using the
MovePlcEvent movement instruction.
If the tested events are present at the end of the movement, the robot continues its
path normally; otherwise, it stops on its path while waiting for the programmed
events to be set.
Example:
MovePlcEvent \L,*\E1,v1000,z20,tool0,wobj0;
Programming a MovePlcEvent instruction
Syntax :
MovePlcEvent
[\L] ToPoint [\E1][\E2][\E3][\E4][\E5][\E6][\E7]
[\E8][\E9][\E10][\E11][\E12][\E13][\E14][\E15]
[\E16] speed zone tool wobj
Mandatory parameters :
Name :
Meaning :
ToPoint
Position, target of the movement, and where events test will

be performed
speed
zone
tool
wobj
Name :
\L
Meaning :
\E1 ... \E16

to be set.
RDNU0006 Revision F
93

7.5 Programming tool commands
7.5
Programming tool commands
Tool command management principles

The tool commands are information signals sent by the robot to a tooling control
cabinet. This logic information can be programmed on positions when creating or
modifying paths.
Note: Tool commands can also be used as an extension of the PLC commands.
The tool commands are only set during program execution. These commands are
generated when a SendTooling action is programmed on a fine point or when
a MoveSendTooling instruction is programmed on a fly-by point:
The tool commands are reset during path teaching, in case of recycling,
when a movement program is aborted or after having moved the robot to
its safe position.
The tool commands are programmed by blocks of 16. The tool

commands not programmed in one instruction are reset. You must the
re-program on an instruction all the commands previously set that you
want to remain set.
7.5.1 SendTooling instruction

This path instruction entitles you to send up to 16 tool commands on the same
position.
Generation of the commands can be delayed using the optional \Delay argument.
This parameter defines the value of the delay in seconds. If this argument is used,
generation of all the programmed commands is delayed.
Example:
SendTooling\O1;
Programming a SendTooling instruction

Syntax:
SendTooling
[\O1][\O2][\O3][\O4][\O5][\O6][\O7][\O8]
[\O9][\O10][\O11][\O12][\O13][\O14][\O15][\O16]
94
Name :
Meaning :
\Delay
Command generation delay in seconds
\O1 ... \O16

set.
RDNU0006 Revision F

7.5 Programming tool commands
7.5.2 MoveSendTooling instruction

Generation of the tool commands can also be programmed using the
MoveSendTooling instruction.
This instruction is used to generate tool commands in the fly-by point zone, but
cannot be used to delay generation of the commands.
Example:
MoveSendTooling \L,*\O1,v1000,z20,tool0,wobj0;
Programming a MoveSendTooling instruction

Syntax:
MoveSendTooling
[\L][\Id] ToPoint [\O1][\O2][\O3][\O4][\O5][\O6]
[\O7][\O8][\O9][\O10][\O11][\O12][\O13][\O14]
[\O15][\O16] speed zone tool wobj
Mandatory parameters:
Name :
Meaning :
ToPoint
Position, target of the movement, where the programmed

commands will be sent
speed
zone
tool
wobj
Name :
\L
Meaning :
\Id
Synchronization identifier for use in synchronous movement
\O1 ... \O16

set.
RDNU0006 Revision F
95

7.6 Programming tool events
7.6
Programming tool events
Tool event management principles

The tool events are information signals expected by the robot and generated by a
tool control cabinet. This logic information can be programmed on positions when
creating or modifying paths.
Note: The tool events can also be used as an extension to the PLC events.
The tool events are only expected during program execution. These events are
expected as soon as a ToolingEvent action is programmed on a fine point, or
when a MoveToolingEvent instruction is programmed on a fly-by point :
The tool events are not expected during path teaching.
Cancelling a movement program aborts the wait for programmed events.
The events can be monitored dynamically. In this case, the last expected
programmed state is the one which is dynamically monitored.
By default, the dynamic monitoring on the events is inactive.
Only the events programmed in one instruction are expected. To check

that previously received events are still present, you must program them
again in further instructions.
7.6.1 ToolingEvent instruction

This path instruction entitles you to wait for up to 16 tool events on the same
position.
Example:
ToolingEvent\E1;
Programming a ToolingEvent instruction

Syntax:
ToolingEvent
[\E1][\E2][\E3][\E4][\E5][\E6][\E7][\E8]
[\E9][\E10][\E11][\E12][\E13][\E14][\E15][\E16]
96
Name :
Meaning :
\E1 ... \E16

to be set.
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7.6 Programming tool events
7.6.2
MoveToolingEvent instruction

The tool events test can also be programmed in the fly-by point zone using the
MoveToolingEvent movement instruction.
If the tested events are present at the end of the movement, the robot continues its
path normally; otherwise, it stops on its path while waiting for the programmed
events to be set.
Example:
MoveToolingEvent\L,*\E1,v1000,z20,tool0,wobj0;
Programming a MoveToolingEvent instruction
Syntax:
MoveToolingEvent
[\L] ToPoint [\E1][\E2][\E3][\E4][\E5][\E6][\E7]
[\E8][\E9][\E10][\E11][\E12][\E13][\E14][\E15]
[\E16] speed zone tool wobj
Mandatory parameters:
Name :
Meaning :
ToPoint
Position, target of the movement, and where events test will

be performed
speed
zone
tool
wobj
Name :
\L
Meaning :
\E1 ... \E16

to be set.
RDNU0006 Revision F
97

7.7 Programming handling sequences
7.7
Programming handling sequences
Handling sequence management principles

The handling sequences have two states: activated and deactivated . They
are controlled (actuator signals are set or reset) and monitored (feedback signals
are checked) according to their desired state. The signals used to control and
monitor the sequences are defined by the integrator.
By default, sequences are controlled and monitored in the same instruction,
GripperAction. However, a sequence can be checked without controlling it, or
controlled without checking it. Control of the sequence without checking can be
programmed indifferently on fly-by points or on fine points. The other modes
require the use of fine points.
98
When the feedback signals associated to sequences are checked on a

point, the robot does not leave the point as long as the check is not
satisfying. If the feedback signals for sequence "n" are not in the
expected state, a message WAITING FOR GRIPPER ACTION: n is
displayed in the Production screen of the application, after a delay
intended to mask the technical time for movement of the actuators.
When the action is completed, the message is cleared and the robot
resumes its sequence without any operator action.
The sequences are then dynamically monitored during movements

between points. This dynamic monitoring can be deactivated. If dynamic
monitoring of the sequences is active, the robot stops in the event of a
faulty check and the message GRIPPER FEEDBACK LOST: n is
displayed in the Production screen of the application. When the
feedback signals return to their expected state, the message is cleared
and the robot resumes its sequence without any operator action.
At the end of a regain to path (repositioning) operation, if dynamic

monitoring of the sequences is active, the program cannot be restarted in
its current path as long as all the sequences are not correct with respect
to their programmed state.
If recycling is performed, with dynamic monitoring of the sequences

active, the sequences are monitored with respect to the state currently
controlled.
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7.7 Programming handling sequences
7.7.1
GripperAction instruction

This instruction is used to control and check, on the same position, up to 16
sequences.
The instruction includes optional arguments used respectively to initiate control, in
the activated state or in the deactivated state, of sequences 1 to 16:
\S1_A or \S1_D
\S16_A or \S16_D
The optional argument \CheckOnly is used to check the sequences without

controlling them.
The optional argument \NoCheck is used to control the sequences without
checking them. In this case, the GripperAction instruction can be used on a
fly-by point.
It is necessary to repeat the control states of the previously controlled sequences in
order to continue to control them if so desired.
Without an optional argument, this instruction can be used to reinitialize the state
of the programmed sequences (to be used, for example, when dropping the tool if a
tool changer is used).
Example:
GripperAction\S1_A;
Programming a GripperAction instruction

Syntax:
GripperAction
[\S1_A][\S1_D][\S2_A][\S2_D][\S3_A][\S3_D]
[\S4_A][\S4_D][\S5_A][\S5_D][\S6_A][\S6_D]
[\S7_A][\S7_D][\S8_A][\S8_D][\S9_A][\S9_D]
[\S10_A][\S10_D][\S11_A][\S1_D][\S12_A][\S12_D]
[\S13_A][\S13_D][\S14_A][\S14_D][\S15_A][\S15_D]
[\S16_A][\S16_D][\Nocheck][\CheckOnly]
RDNU0006 Revision F
Name :
Meaning :
\S1_A \S16_A
Controls sequence 1 to 16 to its activated state
\S1_D \S16_D
Controls sequence 1 to 16 to its deactivated state
\Nocheck
Indicates that the sequences specified in the instruction

are controlled but not checked.
\CheckOnly
Indicates that the sequences specified in the instruction

are checked but not controlled.
99

7.8 Programming part detection functions
7.8
Programming part detection functions
Part detection management principle

The application software manages up to 8 part detection functions using logic
inputs. The choice of name and assignment of the inputs managing the part
detection functions is left to the integrators discretion.
These signals are monitored with respect to their expected state: idle, set or reset.
The expected states of all the part detection functions are placed in the idle state on
program start up from its Main routine. They are then positioned in accordance
with the path programs.
This programming is only performed on a fine point; it is however possible, at any
time, to reposition the expected states of all the part detection functions to the idle
state and thus inhibit monitoring of these states.
When monitoring the part detection functions on a point, if a signal does

not correspond to the expected state, a message " WAITING FOR PART
DETECTION: n ", is displayed on the Production screen of the
application. The n represents the number of the faulty part detection
function. When the signal takes the expected value, the message is
cleared and the involved robot resumes its sequence with no operator
action.
By default, dynamic monitoring of the part detection function is active

and the state of the expected inputs is monitored continuously.
Between points, if there is loss of a part detection indication and if the

function dynamically monitored, the robot stops and the message " PART
DETECTION LOST: n " is displayed in the message area of the
Production screen of the application. Once the error has been fixed,
the robot resumes its sequence without any operator action.
At the end of a repositioning operation, if dynamic monitoring of the

part detection functions is active, the program cannot be restarted on its
current path as long as the part detection signals do not match the
programmed state.
If recycling is performed, the states of all the part detection functions are
positioned to the idle state.
7.8.1 CheckPart instruction

This instruction is used to program the expected state for the 8 part detection
signals and to wait for the signals to match the expected states.
For each part detection function, the programming is used to either:
wait for the corresponding input to be set,
100
wait for the corresponding input to be reset,
ignore the state of the corresponding input.
RDNU0006 Revision F

7.8 Programming part detection functions
If at least one input is expected to be set or reset, the CheckPart instruction
must be programmed on a fine point. If all the states are idle, the instruction can be
programmed on a fly-by point.
This instruction specifies, as optional arguments, the part detection functions to be
checked and their expected state. The argument \DET1_1 indicates that the part
detection sensor 1 is expected to be set (1), the argument \DET1_0 indicates that
the part detection sensor 1 expected to be reset (0), and so on for the 8 part
detection sensors. The expected state is idle for the part detection sensors not
specified in the instruction.
This means that when the expected state of a part detection sensor is modified, the
programming for the other part detection sensors must be repeated in order to
continue to monitor them if so desired.
Example:
CheckPart \CPP1_1;
Programming a CheckPart instruction

Syntax:
CheckPart
[\DET1_1][\DET1_0][\DET2_1][\DET2_0]
[\DET3_1][\DET3_0][\DET4_1][\DET4_0]
[\DET5_1][\DET5_0][\DET6_1][\DET6_0]
[\DET7_1][\DET7_0][\DET8_1][\DET8_0]
Name :
Meaning :
\DETx_1
Part detection input x expected to be 1
\DETx_0
Part detection input x expected to be 0
The application software does not monitor the state of the part detection sensors
not specified in the instruction. Use of the instruction without optional argument
thus results in inhibiting dynamic monitoring of the part detection sensors.
RDNU0006 Revision F
101

7.9 Programming the dynamic monitoring functions
7.9
Programming the dynamic monitoring functions
Dynamic monitoring management principle

This function ensures continuous (between points) monitoring of the states of the
signals corresponding to the part detection sensors, the handling sequences and the
events. For more information, see 4.7.1 Dynamic monitoring.
Each of the dynamic monitoring functions can be enabled or disabled at any
moment using the instruction MonitorInputs.
7.9.1 MonitorInputs instruction

This instruction is used to define the active (enabled) dynamic monitoring
functions.
Two optional argument families can be used: two exclusive general arguments and
3 basic arguments whose effects are cumulative:
Use of the instruction without argument or with argument \NONE

inhibits all the dynamic monitoring functions.
Use of argument \BY_DEFAULT activates the default monitoring

functions defined by the integrator (see 4.7.1. Dynamic monitoring).
Arguments \GRIPPER, \PART, \PLC and \TOOLING respectively

activate dynamic monitoring of the handling sequences, the Part
detection signals, the PLC events and the tool events. When using this
type of argument, the monitoring functions that are not sepcified are
inhibited.
Example:
! activates only dynamic
! sequences
MonitorInputs \GRIPPER;
102
monotoring
of
the
handling
RDNU0006 Revision F

7.9 Programming the dynamic monitoring functions
Programming a MonitorInputs instruction
Syntax:
MonitorInputs
[\NONE] [\BY_DEFAULT]
[\GRIPPER] [\PART] [\PLC] [\TOOLING]
RDNU0006 Revision F
Name :
Meaning :
\NONE
Disables all dynamic monitoring functions ; this is the default

option (when instruction is used without argument)
\BY_DEFAULT
Enables default monitoring functions as defined by the

integrator
\GRIPPER
Enables dynamic monitoring of handling sequences
\PART
Enables dynamic monitoring of part detection sensors
\PLC
Enables dynamic monitoring of PLC events
\TOOLING
Enables dynamic monitoring of tool events
103
8 Service programs
8 Service programs
8.1
General information
The Promia application software manages 4 service programs, each of which can result from a request internal
to the process (example: spot welding), a service frequency (example: arc welding), or a request generated by
an external signal (pushbutton ).
Service request management principle
A service request 1 is thus understood, whatever its source, as a service request
prompting execution of service program 1. The same applies for a service request
2 and so on.
At a given moment, several service requests may be active. The 4 service requests
are managed in accordance with a specific priority:
Service request 1 priority > Service request 2 priority > Service request 3 priority
> Service request 4 priority
RDNU0006 Revision F
105
8 Service programs
106
RDNU0006 Revision F

9.1 Index

9.1
Index
A
Anti-loop function
Principle and management..............................87
D
Debugging
Definition........................................................23
Dynamic monitoring
Description .....................................................48
Programming ................................................102
Types of monitoring .......................................48
E
Errors and messages
Displaying ......................................................57
List of common base errors requiring a
validation ....................................................59
List of common base simple errors.................59
List of simple common base messages ...........61
F
FlexPendant
Basic menu .....................................................34
Dedicated buttons ...........................................33
H
Handling sequences
Definition........................................................22
Manual control................................................73
Programming ..................................................98
Promia window...............................................70
Hazard levels ......................................................11
Home position
definition ........................................................17
I
IRC5
Control devices ...............................................33
P
Part Detection
Definition........................................................22
Programming ................................................100
Promia window...............................................68
PLC Commands
Definition........................................................21
Programming ..................................................90
Promia window...............................................78
RDNU0006 Revision F
PLC Events
Definition ....................................................... 21
Programming .................................................. 92
Promia window .............................................. 76
Program
Display in Production screen.......................... 55
Robot program and path principle.................. 17
Running program in automatic mode ............. 39
Running program in manual mode ................. 38
Program code
Program code priority..................................... 46
sources of program codes ............................... 45
Promia
Customizable modules ................................... 31
Description ..................................................... 14
Organization of memory ................................ 28
Software architecture...................................... 27
R
Recycling
Application software behavior ....................... 50
Definition ....................................................... 19
Repositioning
Application software behavior ....................... 50
Definition ....................................................... 19
S
Safe
end of production request ............................... 44
Safe position
definition of safe position............................... 18
Startup
Execution of start program ............................. 44
Move to safe request....................................... 42
Safe and home requests .................................. 41
T
Tool Commands
Definition ....................................................... 21
Programming .................................................. 94
Promia window .............................................. 78
Tool Events
Definition ....................................................... 21
Programming .................................................. 96
Promia window .............................................. 76
107

9.2 Table of figures
9.2
Table of figures
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
Figure 9.
Figure 10.
Figure 11.
Figure 12.
Figure 13.
Figure 14.
Figure 15.
Figure 16.
Figure 17.
Figure 18.
Figure 19.
Figure 20.
Figure 21.
Figure 22.
Figure 23.
Figure 24.
Figure 25.
Figure 26.
Figure 27.
Figure 28.
Figure 29.
Figure 30.
Figure 31.
Figure 32.
Figure 33.
Figure 34.
Figure 35.
Figure 36.
Figure 37.
Figure 38.
Figure 39.
Figure 40.
Figure 41.
Figure 42.
Figure 43.
Figure 44.
Figure 45.
Figure 46.
Figure 47.
Figure 48.
Figure 49.
Block diagram of PROMIA application software ............................................................ 14

Sequencing of paths ; daisy principle......................................................................... 18
Debug menu ..................................................................................................................... 19
Recycling without manual jogging................................................................................... 19
Repositioning and recycling after manual jogging........................................................... 20
Commands and events...................................................................................................... 21
Tooling commands and events ......................................................................................... 21
Software architecture ....................................................................................................... 27
Organization on the flashdisk........................................................................................... 30
Robot system control devices........................................................................................... 33
Dedicated keys on the FlexPendant.................................................................................. 33
ABB basic menu .............................................................................................................. 34
Choice of program to be edited ........................................................................................ 36
Production window in a single-robot environment .......................................................... 36
Production window in a multi-robot environment ........................................................... 37
Program restarted at beginning (single or multi-robot) .................................................... 38
Confirmation of PP to Main (single or multi-robot)......................................................... 38
Confirmation of automatic mode ..................................................................................... 39
Return to safe position prompt (single robot example) .................................................... 42
Switch to manual mode to initiate direct move to safe operation..................................... 43
Direct move to safe dialog to be acknowledged for robots 1 and 2. ................................ 43
Prompt: OK to Move to Home ? ...................................................................................... 44
Screen container and floating panel ................................................................................. 51
Floating panel control handle ........................................................................................... 51
Application software screen selection button................................................................... 52
Button used to toggle between current screen and Operator Panel screen. ...................... 52
Application software screen selection command bar ....................................................... 52
Selection of "Common Features" screens ........................................................................ 53
The two areas of the Production screen............................................................................ 55
Example of snapshot message area .................................................................................. 56
Example of history area messages.................................................................................... 57
Structure of Promia information screens.......................................................................... 67
Part detection screen : undefined state ............................................................................. 68
Part detection screen : correct state .................................................................................. 69
Part detection screen : wrong state ................................................................................... 69
Page showing general state of sequences ......................................................................... 70
Page showing detailed state of a sequence ....................................................................... 70
General state of Sequences : undefined state ................................................................... 71
Sequence Screen : correct state ........................................................................................ 72
Sequence Screen : feedback error .................................................................................... 72
Detail screen of sequences, manual control not enabled .................................................. 73
Sequence detail screen, manual control enabled .............................................................. 74
Events screen : Correct state ............................................................................................ 76
Events screen : error state................................................................................................. 77
PLC Command Screen ..................................................................................................... 78
Simplified Backup screen........................................................................................... 80
Debug Menu of the Production Window ......................................................................... 83
Acknowledgement of anti-loop message ......................................................................... 87
Calling a path ................................................................................................................... 88
RDNU0006 Revision F
109

9.2 Table of figures
110
RDNU0006 Revision F

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About the Safety section ...................................................................................................9

About the Welcome section ............................................................................................13

Robot program and path principles .....................................................................17

3 Organization of application software

3.6.1 Common base modules .......................................................................................31

General controls of the robot controller ...........................................................................33

"Production enabled" and "Production disabled" modes.....................................40

Principles relative to actions and checks attached to a position......................................47

4.7.1 Dynamic monitoring............................................................................................48

Behaviors in cases of exception......................................................................................50

4.8.1 Behavior during manual jogging .........................................................................50

General description of the screen container....................................................................51

5.3.1 Program area details ............................................................................................55

5.4.1 Common base application messages ...................................................................59

Operator panel screen ....................................................................................................65

General description of the information screen.....................................................66

Backup screen ................................................................................................................79

5.7.1 General description of screen ..............................................................................80

7 Actions on paths common to all processes

Programming anti-loop functions.....................................................................................87

7.3.1 SendPlc instruction ..........................................................................................90

Programming events .......................................................................................................92

7.4.1 PlcEvent instruction ......................................................................................92

Programming tool commands .........................................................................................94

7.5.1 SendTooling instruction.................................................................................94

Programming tool events ................................................................................................96

7.6.1 ToolingEvent instruction ..............................................................................96

Programming handling sequences..................................................................................98

7.7.1 GripperAction instruction............................................................................99

Programming part detection functions...........................................................................100

7.8.1 CheckPart instruction ...................................................................................100

Programming the dynamic monitoring functions ...........................................................102

7.9.1 MonitorInputs instruction..........................................................................102

9 Index and appendices

About this manual

Who is this manual intended for

References Product Documentation

Product Manual, procedures

IRC5 3HAC 021313-001

How to read this manual

names on elements in the

In the Open File dialog

names on keyboard keys

To open the help,

blue italic letters

See The RobotStudio

Product Documentation, M2004

Product Documentation, M2004

Installation and commissioning (descriptions relative to mechanical

Maintenance (descriptions of all required preventive maintenance

Repair (descriptions of all recommended repair procedures, including

Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

About the Safety section

Safety standards applicable to IRC5