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S4Cplus/IRC5
 Calibration Pendulum Instruction

Document ID: 3HAC 16578-1

Revision: E
Copyright 2003-2007 ABB. All rights reserved.
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 ABBs 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.

Copyright 2003-2007 ABB. All rights reserved.

Copyright 2003-2007 ABB All rights reserved.

ABB Robotics
SE-721 68 Vsters
Sweden
 7DEOHRI&RQWHQWV

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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1.1 To what robots does this apply? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 When to calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Types of calibration procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Equipment for calibration pendulum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.6 Storage and warm up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Start up of Levelmeter 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3 Calibration of sensors (calibration pendulum) and Levelmeter 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4 Checking of sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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3.1 Different functions in the calibration service routine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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3.2.1 About Calibration Pendulum II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2.2 Preparing the calibration procedure, CalPend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2.3 Calibration, all axes, CalPend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.2.4 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.2.5 Calibration sensor mounting positions, CalPend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2.6 Preparation for using sensor on axes 1 and 6, CalPend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2.7 Calibration Pendulum II procedure on TPU, S4Cplus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.2.8 Calibration Pendulum II procedure on FlexPendant, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.2.9 Post calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.2.10 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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3.3.1 About Reference Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.3.2 Preparation of reference surface at tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.3.3 Defining reference values for calibration of axes 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.3.4 Preparing the calibration procedure, RefCal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.3.5 Calibration of axes 2-6 using predefined reference values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Copyright 2003-2007 ABB. All rights reserved.

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3HAC 16578-1 Revision: E 3

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3HAC 16578-1 Revision: E

Copyright 2003-2007 ABB. All rights reserved.
 Overview

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This manual contains procedures for calibrating a robot, using the tool calibration pendulum.
Both the Calibration Pendulum II and Reference Calibration routine are described.

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This manual should be used during calibration with the calibration pendulum.

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This manual is intended for:
installation personnel on the installation site.
repairing personnel during repair or maintenace.

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The reader should have...
the required knowledge of how the robot works
a basic understanding of what calibration does and how it is performed.

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The manual is organized in the following chapters:

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1. General information about the calibration method, including information about
the required tools.
2. Information about how to prepare the equipment prior to calibration.
3. Procedures that detail how to perform the calibration. The chapter is divided in
two sections, one for each routine (Calibration Pendulum II and Reference Cal-
ibration). The sections specify to which robot system the routine is applicable.
Copyright 2003-2007 ABB. All rights reserved.

5HYLVLRQV

5HYLVLRQ 'HVFULSWLRQ
0 First edition.
A Information on IRB 7600/2.3/500 added.
Paths to calibration software revised.
Minor editorial changes.
B Minor editorial changes.
Methods to calibrate the pendel tool added.
Changes in Information about IRB 7600/2.3/500.
C Pendellum Calib II intrud.
Methods to calibrate the pendel tool added for IRC5.
Changes in Information about IRB 7600/2.3/500.
D Reference Calibration introduced.
Manual restructured.
Robot models IRB 1600, IRB 260, IRB 660, IRB 4450S and IRB 6600ID/6650ID
added to the calibration procedure.

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3HAC 16578-1 Revision: E 5

Overview

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E Robot model IRB 1600ID added to the calibration procedure.

Copyright 2003-2007 ABB. All rights reserved.

6 3HAC 16578-1 Revision: E

 *HQHUDOLQIRUPDWLRQ
1.1. To what robots does this apply?

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Robots, in general, may be calibrated using a number of methods. This manual describes
robot calibration using the Calibration Pendulum method, which is applicable to the
following ABB robots:

5RERWPRGHO 6HULDOQXPEHU
IRB 140 14M-21493
IRB 1400 14-26001
IRB 1600 All robots.
IRB 2400 M2000 24-23050 and on.
Robots with serial numbers 24-23051, 24-23052, 24-23054, 24-23055,
24-23056 and 24-23061 were not calibrated using the calibrations
pendulum method before delivery from ABB, but these robots are fully
compatible with this method.
IRB 260 All robots.
IRB 4400 M2000 44-21782 and on.
IRB 4450S All robots.
IRB 660 All robots.
IRB 6600/6650 All robots.
IRB 6600ID/6650ID All robots.
IRB 7600 76-20187 and on.
127( Robots 76-20190 and 76-20191 are H[FOXGHG!
IRC5 M2004 All robots using IRC5 controller.
Copyright 2003-2007 ABB. All rights reserved.

3HAC 16578-1 Revision: E 7

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1.2. When to calibrate

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The system must be calibrated if one or more of the listed failures below occurs.

Changed resolver values

Calibrate the measurement system carefully as detailed in chapter &DOLEUDWLRQRQSDJH if
any of the resolver values has been changed. This may occur when parts affecting the
calibration position have been replaced on the robot.

Contents of the revolution counter memory are lost

Calibrate the system roughly as detailed in section 8SGDWLQJUHYROXWLRQFRXQWHUVRQSDJH
if the contents of the revolution counter memory are lost. This may occur when:
the battery has been discharged
a resolver error occurs
the signal between a resolver and measurement board interrupted
a robot axis has been moved while the control system was disconnected.

Copyright 2003-2007 ABB. All rights reserved.

8 3HAC 16578-1 Revision: E

 *HQHUDOLQIRUPDWLRQ
1.3. Types of calibration procedures

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The routine Calibration Pendulum II (CalPend) is used to move the robot to zero position for
fine calibration of motor calibration offset. The calibration is fully automatic and will move
the robot to the position read from the sensors.
Read more about the routine in section $ERXW&DOLEUDWLRQ3HQGXOXP,,RQSDJH.
If the second generation of tool set is available it is always recommended to use the flip-flop
variant (option available for IRB 6600/6650 and IRB 7600). (In the second generation of tool
set the calibration pendulum housing is equipped with an extra pin on the side, next to the
attachment screw. The service routine will ask the operator whether to use the flip-flop variant
or not.)
From RobotWare 4.0.100 (M2000) and 5.07 (M2004) automatic fine calibration is available
in the service routine.

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With the routine Reference Calibration (RefCal) references are taken of the robots zero
position once the robot is installed. These reference values are then used when the robot needs
to be recalibrated at future service occasions, i.e. recalibration of the motor calibration offset
is required.
Read more about the routine in section $ERXW5HIHUHQFH&DOLEUDWLRQRQSDJH.
The Reference Calibration includes features regarding:
axis 1 position. The user may put the axis 1 in any position, to avoid obstacles.
tool and process equipment. All tool and process equipment may stay fitted during
calibration.
hanging robot. A reference may be used on hanging robots as well.
These features are not available in Calibration Pendulum II.
Copyright 2003-2007 ABB. All rights reserved.

3HAC 16578-1 Revision: E 9

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1.4. Calibration scales and correct axis position

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This section specifies the calibration scale positions and/or correct axis position for all robot
models.

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The illustration below shows the calibration scale positions on IRB 140:

Copyright 2003-2007 ABB. All rights reserved.

xx0200000157

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10 3HAC 16578-1 Revision: E
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1.4. Calibration scales and correct axis position

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The illustration below shows the calibration scale positions on IRB 1400:

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Copyright 2003-2007 ABB. All rights reserved.

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3HAC 16578-1 Revision: E 11
*HQHUDOLQIRUPDWLRQ
1.4. Calibration scales and correct axis position

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The illustration below shows the calibration marks and correct positions of the six axes of the
robot. The marks shown in the figure are numbered according to the number of the axes.

Copyright 2003-2007 ABB. All rights reserved.

xx0500001423

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12 3HAC 16578-1 Revision: E
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1.4. Calibration scales and correct axis position

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Copyright 2003-2007 ABB. All rights reserved.

xx0600002876

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3HAC 16578-1 Revision: E 13
*HQHUDOLQIRUPDWLRQ
1.4. Calibration scales and correct axis position

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The illustration below shows the calibration marks and correct positions of the six axes of the
robot. The marks shown in the figure are numbered according to the number of the axes.

Copyright 2003-2007 ABB. All rights reserved.

xx0700000095

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14 3HAC 16578-1 Revision: E
 *HQHUDOLQIRUPDWLRQ
1.4. Calibration scales and correct axis position

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The illustration below shows the calibration marks on all axes of the robot.
Copyright 2003-2007 ABB. All rights reserved.

en0200000273

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3HAC 16578-1 Revision: E 15
*HQHUDOLQIRUPDWLRQ
1.4. Calibration scales and correct axis position

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When axis 3 is put in calibration position, the mark on the calibration plate is visible above
the mechanical stop, as shown in the figure below.

Copyright 2003-2007 ABB. All rights reserved.

xx0500002485

A Mechanical stop of axis 3

B Calibration mark on calibration plate, axis 3
C Calibration plate and marking, axis 6
D Punch, axis 1, 3HAB8223-1
E Punch, axis 2, 3HAB8223-1 (1 marking)

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16 3HAC 16578-1 Revision: E
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1.4. Calibration scales and correct axis position

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The illustration below shows the calibration scale positions on IRB 4450S.
The calibration marks for axes 2, 3, 4 and 5 are marked using punch mark tools.
Copyright 2003-2007 ABB. All rights reserved.

xx0500002239

A Punch axis 2, 3HAB 1521-1

B Punch axis 3, 3HAB 1522-1
C Punch axis 4, 3HAB 1523-1 (there are two different versions of the marks, as
shown in the figure)
D Punch axis 5, 3HAB 1524-1
E Axes 5 and 6, IRB 4400/L10

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3HAC 16578-1 Revision: E 17
*HQHUDOLQIRUPDWLRQ
1.4. Calibration scales and correct axis position

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The illustration below shows the calibration scale positions on IRB 4400.
The calibration marks for axes 2, 3, 4 and 5 are marked using punch mark tools.

Copyright 2003-2007 ABB. All rights reserved.

xx0300000209

A Punch, axis 2, 3HAB 1521-1

B Punch, axis 3, 3HAB 1522-1
C Punch, axis 4, 3HAB 1523-1 (there are two different versions of the marks,as shown
in the figure)
D Punch, axis 5, 3HAB 1524-1
E Axes 5 and 6, IRB 4400/L10

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18 3HAC 16578-1 Revision: E
 *HQHUDOLQIRUPDWLRQ
1.4. Calibration scales and correct axis position

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The illustration below shows the positions of the calibration marks on the robot.

xx0500002487
Copyright 2003-2007 ABB. All rights reserved.

A Calibration plate, axis 1

B Calibration tab on robot
C Calibration mark, axis 2
D Calibration mark, axis 3
E Calibration plate and marking, axis 6

Calibration marks at axes 2 and 3

The calibration marks at axes 2, 3 and 6 shown in the figure above, consist of two single
marks that should be positioned opposite to one another when the robot is standing in its
calibration position. One of the marks is more narrow than the other and should be positioned
within the limits of the wider mark.

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3HAC 16578-1 Revision: E 19
*HQHUDOLQIRUPDWLRQ
1.4. Calibration scales and correct axis position

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The illustration below shows the location of the calibration scales on specific plates and the
calibration marks directly in the casting at axes 2 and 3.
The figure shows IRB 6600, but the scales and their positions are the same for IRB 6650S
and IRB 7600.

xx0200000176

A1 Calibration scale, axis 1 (early design)

A2 Calibration scale, axis 1 (later design)
B1 Calibration scale, axis 2 (early design)
B2 Calibration mark, axis 2 (later design)
C1 Calibration scale, axis 3 (early design)
C2 Calibration mark, axis 3 (later design)

Copyright 2003-2007 ABB. All rights reserved.

D Calibration scale, axis 4
E Calibration scale, axis 5
F Calibration scale, axis 6

Calibration marks at axes 2 and 3

The calibration marks at axes 2, 3 and 6 shown in the figure above, consist of two single
marks that should be positioned opposite to one another when the robot is standing in its
calibration position. One of the marks is more narrow than the other and should be positioned
within the limits of the wider mark.

&RQWLQXHVRQQH[WSDJH
20 3HAC 16578-1 Revision: E
 *HQHUDOLQIRUPDWLRQ
1.4. Calibration scales and correct axis position

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The illustration below shows the location of the calibration scales on specific plates and the
calibration marks directly in the casting at axes 2 and 3.

xx0500002016

A Calibration scale, axis 1

B Calibration mark, axis 2
C Calibration mark, axis 3
D Calibration scale, axis 4
E Calibration plate, axis 5
F Calibration plate, axis 6

Calibration marks at axes 2 and 3

Copyright 2003-2007 ABB. All rights reserved.

The calibration marks at axes 2, 3 and 6 shown in the figure above, consist of two single
marks that should be positioned opposite to one another when the robot is standing in its
calibration position. One of the marks is more narrow than the other and should be positioned
within the limits of the wider mark.

&RQWLQXHVRQQH[WSDJH
3HAC 16578-1 Revision: E 21
*HQHUDOLQIRUPDWLRQ
1.4. Calibration scales and correct axis position

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The illustration below shows the positions of the calibration marks on all axes of the robot.

Copyright 2003-2007 ABB. All rights reserved.

xx0600003096

A Calibration scale, axis 1

B Calibration scale, axis 2
C Calibration scale, axis 3
D Calibration scale, axis 4
E Calibration scale, axis 5
F Calibration scale, axis 6

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22 3HAC 16578-1 Revision: E
 *HQHUDOLQIRUPDWLRQ
1.4. Calibration scales and correct axis position

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The figure below shows the positions of the calibration marks on the robot.
Copyright 2003-2007 ABB. All rights reserved.

xx0700000148

A Calibration plate, axis 1

B Calibration tab on robot
C Calibration mark, axis 2
D Calibration mark, axis 3
E Calibration mark, axis 4
F Calibration mark, axis 5
G Calibration mark, axis 6

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1.4. Calibration scales and correct axis position

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Axis 4 has no mechanical limitation! Cabling inside the manipulator may be damaged if axis
4 is oriented incorrectly when performing calibration of the robot!

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The figure below shows the calibration marks of the axes 4-5-6 and the correct position of the
spiral cable. The orientation of axis 4 must be specially checked and corrected, if necessary,
before performing any calibration!
The figure also shows the calibration distance on the axes 1-2-3.
If the position of any axis needs to be changed, this is described in the procedures below.

Copyright 2003-2007 ABB. All rights reserved.

xx0200000341

A Axis 4 (center tube)

B Spiral cable inspection cover
C Correct orientation of the spiral cable (and axis 4)
D Index marks for axis 4
E Index marks for axis 5
F Index marks for axis 6
G Calibration distance for axes 1-2-3: 26 mm on each axis

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24 3HAC 16578-1 Revision: E
 *HQHUDOLQIRUPDWLRQ
1.4. Calibration scales and correct axis position

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The axes 1-2-3 should be positioned with an approximate distance of 26 mm between the
actuator and the calibration spacer above the lower joint, shown in the figure above. This
distance is set exactly during the fine calibration procedure.

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The procedure below details how to check and eventually correct the orientation of axis 4.

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1. Remove the VSLUDOFDEOHLQVSHFWLRQFRYHU on the Shown in the figure &DOLEUDWLRQ
center tube sleeve by removing its 4 attachment VFDOHVDQGSRVLWLRQV,5%RQ
screws. SDJH!
2. Make a visual check of the markings on the spiral Directions are detailed in section
cable. 'LUHFWLRQVIRUDOOD[HV.
The markings must be positioned in a straight line,
as shown in the figure &DOLEUDWLRQVFDOHVDQG
SRVLWLRQV,5%RQSDJH!
3. In case correction is necessary, turn axis 4 with the
TPU into the approximate calibration position by
positioning the numbers into a straight line!
4. Refit the spiral cable inspection cover with the 4
attachment screws!

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The procedure below details the correct orientation of axes 5-6.

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1. Make sure that the FDOLEUDWLRQVFDOHV of axis 5 are Calibration scales are shown in the
roughly aligned. figure &DOLEUDWLRQVFDOHVDQG
SRVLWLRQV,5%RQSDJH!
Directions are detailed in section
'LUHFWLRQVIRUDOOD[HV.
Copyright 2003-2007 ABB. All rights reserved.

2. Make sure that the FDOLEUDWLRQVFDOHV of axis 6 are Shown in the figure &DOLEUDWLRQVFDOHV
roughly aligned. DQGSRVLWLRQV,5%RQSDJH!
Directions are detailed in section
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3HAC 16578-1 Revision: E 25

*HQHUDOLQIRUPDWLRQ
1.5. Equipment for calibration pendulum

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Calibration with calibration pendulum requires specific equipment, specified in this section.

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The table below specifies all the equipment required to calibrate all robot models using the
calibration pendulum method.

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Calibration pendulum set 3HAC 15716-1 The content is specified in the table below.
The set may only be rented from ABB,
please contact the Service Department.
Reference adapter 3HAC 025397-001 Used as reference surface on the tool
when calibrating the robot system with
Reference Calibration.
Isopropanol 11771012-208 For cleaning the sensor attachment points.

Contents of calibration pendulum set 3HAC 15716-1

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2 Inclinometer, Wyler 3HAC 12837-7
Zerotronic
1 Cable set Wyler 3HAC 020841- All required cables.
001
1 Leveltronic NT/41 3HAC 15732-1
1 Calibration pendulum 3HAC 4540-1 Used as both a calibration sensor and a
reference sensor, depending on its
function at the time.
1 Turning disk adapter 3HAC 16423-1 May be turned both ways to fit IRB 140,
IRB 1400, IRB 1600, IRB 2400, IRB 4400
and IRB 4450S.

Copyright 2003-2007 ABB. All rights reserved.

Includes all guide pins and attachment
screws.
Also see the following figure!
1 Sync plate 3HAC 021287-
001
1 Calibration plate 3HAC 020552- Required when calibrating the pendulum.
002
4 Batteries For battery supply of "Leveltronic NT/41".
1 Thread tap, M8 For repairing any damaged protective
cover attachment holes.
5 Protective covers and For replacing any damaged protective
attachment screws covers.
1 Locating pin 3HAC 14137-1 58 mm long
For axis 1 calibration of IRB 1600, IRB
660, IRB 6600 and IRB 7600.

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26 3HAC 16578-1 Revision: E
 *HQHUDOLQIRUPDWLRQ
1.5. Equipment for calibration pendulum

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1 Locating pin 3HAC 14137-2 68 mm long
For axis 1 calibration of IRB 140, IRB
1400, IRB 2400, IRB 260, IRB 4400 and
IRB 4450S.
1 Calibration bar 3HAC 024702- For axis 6 calibration of IRB 260 and IRB
001 660.
1 User documentation 3HAC 16578

Illustration, turning disk adapter

May be turned both ways to fit IRB 140, IRB 1400, IRB 2400 and IRB 4400.

xx0200000276

A Guide pin 8 mm
B Guide pin, 6 mm
C Screw, M10
D Screw, M6
Copyright 2003-2007 ABB. All rights reserved.

3HAC 16578-1 Revision: E 27

*HQHUDOLQIRUPDWLRQ
1.6. Storage and warm up

6WRUDJHDQGZDUPXS

127(
Always store the pendulum sensor in its carrying bag laying down or mounted on the
calibration plate in a horizontal position.
6WRUDJHLQDQRQKRUL]RQWDOSRVLWLRQPD\FDXVHORQJWHUPGULIWDQGHUURUVLQWKH:\OHU
VHQVRUV

6WRUDJHDQGZDUPXS
After storage the pendulum tool must be mounted in a horizontal position and be warmed up
(power on) for at least 5 minutes before use.
Storage position or warm up position is illustrated below

xx0300000152

A Calibration pendulum 3HAC 4540-1

B Calibration plate 3HAC 020552-002 Copyright 2003-2007 ABB. All rights reserved.

28 3HAC 16578-1 Revision: E

 3UHSDULQJWKHHTXLSPHQW
2.1. Introduction

3UHSDULQJWKHHTXLSPHQW
,QWURGXFWLRQ

*HQHUDO
This chapter details the required procedures for preparing the calibration equipment prior to
calibration of the robot.
Copyright 2003-2007 ABB. All rights reserved.

3HAC 16578-1 Revision: E 29

3UHSDULQJWKHHTXLSPHQW
2.2. Start up of Levelmeter 2000

6WDUWXSRI/HYHOPHWHU

/D\RXWDQGFRQQHFWLRQRI/HYHOPHWHU
The figure below shows the layout and connection of the Levelmeter 2000.

A B C
xx0200000126

A Connection sensor A
B Connection sensor B
C Connection SIO 1
D Selection pointer
E Measuring unit

3UHSDUDWLRQVVHWWLQJRI/HYHOPHWHU
The procedure below details the initial preparations of the Levelmeter.

Copyright 2003-2007 ABB. All rights reserved.

$FWLRQ
1. Warm up the Levelmeter 2000 for at least 5 minutes before use, if turned off.
2. Set the measuring unit of the angle (DEG) to a sensibility of three decimals, e.g. 0.330.

6WDUWXSRI/HYHOPHWHU
Shown below is an outline of how to initialize the Levelmeter 2000. Detailed procedures are
specified in the manual supplied by the manufacturer.

$FWLRQ 1RWH
1. Connect the measuring unit and sensor using
the included cables.
2. Power up the Levelmeter 2000. Power sources are detailed in 3RZHU
VRXUFHVRI/HYHOPHWHURQSDJH.
3. Connect sensors A and B. Detailed in ,GHQWLI\VHQVRUVRQSDJH.

&RQWLQXHVRQQH[WSDJH
30 3HAC 16578-1 Revision: E
 3UHSDULQJWKHHTXLSPHQW
2.2. Start up of Levelmeter 2000

&RQWLQXHG

$FWLRQ 1RWH
4. 0 connect the Levelmeter 2000 to the Shown in the figure /D\RXWDQG
COM2 port in the control cabinet through the FRQQHFWLRQRI/HYHOPHWHURQSDJH
connector marked 287FRQQHFWLRQ6,2. .
0 connect the Levelmeter 2000 to the
COM1 port in the control cabinet through the
connector marked 287FRQQHFWLRQ6,2.
5. Calibrate the robot!

3RZHUVRXUFHVRI/HYHOPHWHU
Two alternatives are available:
Battery mode: turn on the Levelmeter by pressing ON/MODE until display flashes.
This will eliminate battery saving mode. Do not forget to turn off after use.
External power: connect the power cords (red/black) to 12-48 VDC, found in the
cabinet or external transformer.

$GGUHVV

 $FWLRQ 1RWH
1. Make sure the sensors have different addresses. Any Detailed in the documentation
addresses will do, as long as they differ from each supplied by sensor manufacturer,
other. found in the calibration tool set.

,GHQWLI\VHQVRUV

 $FWLRQ 1RWH
1. Connect the sensor to the VHQVRUFRQQHFWLRQ points. Marked $ and %.
Shown in the figure /D\RXWDQG
FRQQHFWLRQRI/HYHOPHWHU
RQSDJH.
2. Press 2102'(.
3. Press 2102'( until the dot flashes under 6(1625.
Copyright 2003-2007 ABB. All rights reserved.

4. Press ENTER.
5. Press =(526(/(&7 arrows until a flashing "A B" is
shown.
6. Press (17(5
Wait until the "A B" flashes again.
7. Press (17(5

5HVXOW
The Levelmeter 2000 is now initialized and ready for service.

3HAC 16578-1 Revision: E 31

3UHSDULQJWKHHTXLSPHQW
2.3. Calibration of sensors (calibration pendulum) and Levelmeter 2000

&DOLEUDWLRQRIVHQVRUVFDOLEUDWLRQSHQGXOXPDQG/HYHOPHWHU

*HQHUDO
The tool calibration pendulum is used as both a calibration and a reference sensor. The sensor
needs to be calibrated in order to give proper calibration result.
Calibration of the sensors is only required for RobotWare 4.0.100 and earlier as well as for
RobotWare 5.04 and earlier. Later releases of the RobotWare include the sensor calibration in
its service routine.
4.0.110 (and later) and 5.05 (and later): QHYHU use "skip" when performing calibration and
asked for sensor calibration "zero setting" unless you are running the second repeatative
calibration on RQH robot at RQH occasion. For these the initial sensor calibration vill still be
valid.

6HQVRUILWWHGWRWKHFDOLEUDWLRQSODWH

Copyright 2003-2007 ABB. All rights reserved.

xx0300000152

A Sensor (calibration pendulum, 3HAC 4540-1)

B Calibration plate (3HAC 020552-002)

&RQWLQXHVRQQH[WSDJH
32 3HAC 16578-1 Revision: E
 3UHSDULQJWKHHTXLSPHQW
2.3. Calibration of sensors (calibration pendulum) and Levelmeter 2000

&RQWLQXHG

&DOLEUDWLRQRIVHQVRUV
The procedure below details how to calibrate the sensors.
From RobotWare 4.0.110 (M2000) and 5.05 (M2004) calibration of the sensors is included in
the service routine. Follow the procedure below for earlier RobotWare releases.

$FWLRQ 1RWH,OOXVWUDWLRQ
1. Place the calibration plate on a steady and flat Shown in the figure 6HQVRUILWWHGWR
foundation. Clean the calibration plate surface WKHFDOLEUDWLRQSODWHRQSDJH.
with isopropanol.
Clean the three contact surfaces of the sensor
with isopropanol.
Fit the sensor in one of the two possible positions.
2. Press repeatedly the button ON/MODE until the
marker moves to the text SENSOR.
3. Press repeatedly the button ENTER.
4. Press repeatedly the button ZERO/SELECT until
A appears under the Port/Sensor.
5. Press the button ENTER and wait until A stops
flashing.
6. Press the button ON/MODE until the marker
moves to the text ZERO.
7. Press the button ENTER. The direction indicator
(+/-) and the last zero-offset will be displayed. Wait
a couple of seconds for the sensors to stabilize.
8. Press the button HOLD and wait until the marker
under ZERO starts to blink.
9. Remove the pendelum tool, turn it 180 and fit the
tool in the corresponding hole pattern.
1RWH'RQRWFKDQJHWKHSRVLWLRQRIWKH
FDOLEUDWLRQSODWH
Wait a couple of seconds for the sensors to
stabilize.
Copyright 2003-2007 ABB. All rights reserved.

xx0300000207

10. Press the button HOLD and wait a couple of

seconds. The new zero offset will be displayed.
11. Press the button ENTER, now the sensor is
calibrated and should display the same value, but
with different direction (+/-) for the two positions.
12. Adjust the instrument as described in step 2- 5, to
read the sensor B.
13. Repeat the actions described in step 6 - 11.
14. Adjust the instrument as described in step 2- 5, to
read the sensor AB.
15. Check the results. Detailed in section &KHFNLQJRI
VHQVRUVRQSDJH.

3HAC 16578-1 Revision: E 33

3UHSDULQJWKHHTXLSPHQW
2.4. Checking of sensors

&KHFNLQJRIVHQVRUV

*HQHUDO
This section details how to check the sensors if they have been manually calibrated according
to section &DOLEUDWLRQRIVHQVRUVFDOLEUDWLRQSHQGXOXPDQG/HYHOPHWHURQSDJH.
No check is necessary if the sensors have not been calibrated manually.

6HQVRUILWWHGWRFDOLEUDWLRQSODWH

xx0300000152

A Sensor (calibration pendulum) (3HAC 4540-1)

B Calibration plate (3HAC 020552-002)

Copyright 2003-2007 ABB. All rights reserved.

&KHFNRIVHQVRU
The procedure below details how to check individual sensors with the Levelmeter 2000.

$FWLRQ 1RWH,OOXVWUDWLRQ
1. Place the calibration plate on a steady and
flat foundation. Clean the surface of the
calibration plate with isopropanol.
Clean the contact surface of the sensor
with isopropanol.
Fit the sensor in one of the two possible
positions.
2. Adjust the instrument to read the sensor If the instrument reads anything else,
A and B. adjust it as described in step 2- 5,
&DOLEUDWLRQRIVHQVRUVRQSDJH.
3. Wait a couple of seconds for the sensors to
stabilize, read the value shown by the
instrument.

&RQWLQXHVRQQH[WSDJH
34 3HAC 16578-1 Revision: E
 3UHSDULQJWKHHTXLSPHQW
2.4. Checking of sensors

&RQWLQXHG

$FWLRQ 1RWH,OOXVWUDWLRQ
4. Remove the sensor, turn it 180 and refit it
in the corresponding hole pattern. wait a
couple of seconds until the sensor has
been stabilized.
1RWH'RQRWFKDQJHWKHSRVLWLRQRIWKH
FDOLEUDWLRQSODWH

xx0300000261

5. Read the values for A and B shown by Detailed in step 1-15 in &DOLEUDWLRQRI
the instrument. The difference between the VHQVRUVRQSDJH.
two readings should be less than 0.002
and have opposite directions (+/-). If the
difference is greater, the sensor must be
recalibrated.
Copyright 2003-2007 ABB. All rights reserved.

3HAC 16578-1 Revision: E 35

3UHSDULQJWKHHTXLSPHQW
2.4. Checking of sensors

Copyright 2003-2007 ABB. All rights reserved.

36 3HAC 16578-1 Revision: E

 &DOLEUDWLRQ
3.1. Different functions in the calibration service routine

&DOLEUDWLRQ
'LIIHUHQWIXQFWLRQVLQWKHFDOLEUDWLRQVHUYLFHURXWLQH

7\SHVRIFDOLEUDWLRQ
The calibration service routine consists of two different parts:
Calibration Pendulum II (robot home position, CalPend)
Reference Calibration (RefCal). Only for M2004 robot systems.

(YROXWLRQRYHUYLHZ
The table below shows the introduced functions in the calibration service routine.
,QFOXGHGLQVHUYLFH
)XQFWLRQ 1RWH
URXWLQHDVIURP
0 0
Calibration of sensors and 4.0.110 5.0.5 Done manually in earlier
Levelmeter 2000 releases.
Automatic fine calibration 4.0.100 5.0.7 Switching of windows and
performing manual fine
calibration no longer needed.
New high performance calibration 4.0.110 5.0.5 Eliminates calibration of axis
routine (called flip-flop) for IRB 3/4 on the upper arm.
6600/6650/7600
Reference calibration not 5.0.7 Only valid for 6-axis robots.
available
Copyright 2003-2007 ABB. All rights reserved.

3HAC 16578-1 Revision: E 37

&DOLEUDWLRQ
3.2.1. About Calibration Pendulum II

&DOLEUDWLRQ3HQGXOXP,,

$ERXW&DOLEUDWLRQ3HQGXOXP,,

8VDJHRI&DOLEUDWLRQ3HQGXOXP,,
The Calibration Pendulum II is used in field, to restore the robot home position, eg. after
service activities. (Calibration Pendulum II is a function included in the service routine
Calibration Pendulum.)

7KHSULQFLSOHRI&DOLEUDWLRQ3HQGXOXP,,
In the calibration procedure the position of the sensor is first measured at the reference plane.
Then the pendulum calibration sensor is placed on each axis and the robot is run to its
calibration position, thus reducing the sensor difference to close to zero.

3HULSKHUDOHTXLSPHQW
The robots upper arm must be free from any peripheral equipment during calibration. Fitted
tools and similar ZLOO cause erroneous calibration positions.

5HTXLUHGWRROV
Required tools for performing the Calibration Pendulum II procedure are specified in section
(TXLSPHQWIRUFDOLEUDWLRQSHQGXOXPRQSDJH.

Copyright 2003-2007 ABB. All rights reserved.

38 3HAC 16578-1 Revision: E

 &DOLEUDWLRQ
3.2.2. Preparing the calibration procedure, CalPend

3UHSDULQJWKHFDOLEUDWLRQSURFHGXUH&DO3HQG

*HQHUDO
This section details all required preparations for performing Calibration Pendulum II
(CalPend).

3UHSDUDWLRQVIRUFDOLEUDWLRQSURFHGXUH
127(
%HIRUHXVHRIWKH3HQGXOXP&DOLEUDWLRQDOOH[WHUQDOD[LV!PXVWEHGLVFRQQHFWHG
RQO\UHTXLUHGIRU5RERW:DUHRUHDUOLHU

 $FWLRQ 1RWH
1. Make sure the robot is prepared for calibration. Detailed in the 3URGXFWPDQXDO for
(i.e. all service or installation activities are each robot.
completed and the robot is ready to run.)
2. Check that all required hardware is available for Specified in section (TXLSPHQWIRU
calibrating the robot. FDOLEUDWLRQSHQGXOXPRQSDJH.
3. Remove all peripheral equipment from the upper
arm of the robot (eg. tools and dresspack).
4. Remove all the covers for the surfaces where to Mounting locations of reference and
fit the calibration and reference sensors and calibration sensors are shown in
clean them with isopropanol. section &DOLEUDWLRQVHQVRUPRXQWLQJ
1RWH The same calibration pendulum is used as SRVLWLRQV&DO3HQGRQSDJH.
a calibration sensor and as a reference sensor
depending on its function at the time. In the
calibration procedure the pendulum will be called
calibration sensor or reference sensor
depending on its function at the time.
5. Clean the guide pin holes. Use isopropanol.
6. Connect the calibration equipment to the robot Specified in section 6WDUWXSRI
controller and start up the Levelmeter 2000. /HYHOPHWHURQSDJH.
7. Calibrate the robot. Detailed in section &DOLEUDWLRQDOO
D[HV&DO3HQGRQSDJH.
Copyright 2003-2007 ABB. All rights reserved.

8. Verify that the calibration was successfully Detailed in 3RVWFDOLEUDWLRQSURFHGXUH

carried out. RQSDJH.

3HAC 16578-1 Revision: E 39

&DOLEUDWLRQ
3.2.3. Calibration, all axes, CalPend

&DOLEUDWLRQDOOD[HV&DO3HQG

*HQHUDO
This section details how to perform the actual fine calibration of each axis using the
calibration pendulum tools, specified in section (TXLSPHQWIRUFDOLEUDWLRQSHQGXOXPRQSDJH
.

6HQVRUPRXQWLQJSRVLWLRQV
The positions where to fit the calibration pendulum (sensor) differ between different models
and different axes. The positions are shown in &DOLEUDWLRQVHQVRUPRXQWLQJSRVLWLRQV
&DO3HQGRQSDJH.

&DOLEUDWLRQVHTXHQFH
The axes must be calibrated in increasing sequence, i.e. 1 - 2 - 3 - 4 - 5 - 6.

&DOLEUDWLRQZLWKFDOLEUDWLRQSHQGXOXP
The procedure below details how to fine calibrate the robot with calibration pendulum.

 $FWLRQ 1RWH
1. Prepare the robot calibration as detailed
in section 3UHSDULQJWKHFDOLEUDWLRQ
SURFHGXUH&DO3HQGRQSDJH.
2. Jog the robot axes to be calibrated to a Use the calibration scales fitted to each robot
position close to the correct calibration axis to locate this position, shown in section
position. &DOLEUDWLRQVFDOHVDQGFRUUHFWD[LVSRVLWLRQRQ
SDJH.
3. Make a rough calibration. Detailed in section 8SGDWLQJUHYROXWLRQ
FRXQWHUVRQSDJH.
4. 9DOLGIRUD[LVRQO\ Shown in section &DOLEUDWLRQVHQVRUPRXQWLQJ
Fit the ORFDWLQJSLQ to the robot base. SRVLWLRQV&DO3HQGRQSDJH.
Make sure the attachment surface is
clean and free from any nicks or burrs.
5. Start the calibration service routine from The mounting positions for the reference Copyright 2003-2007 ABB. All rights reserved.
the teach pendant unit, and follow the sensor and calibration sensor respectively,
instructions given, including fitting the are shown in &DOLEUDWLRQVHQVRUPRXQWLQJ
calibration sensor when requested. SRVLWLRQV&DO3HQGRQSDJH.
1RWH After fitting the sensor on the robot 1RWH No additional tool is required for fitting
as specified on the teach pendant unit,  the calibration pendulum for axes 1-3!
FOLFNLQJ2.ZLOOVWDUWURERW Fitting the pendulum to the turning disk
PRYHPHQW! requires an adapter (included in the complete
Make sure nobody is within the working set). Notice that there are two adapters!
range of the robot! Article numbers are specified in section
&RQWHQWVRIFDOLEUDWLRQSHQGXOXPVHW+$&
RQSDJH.
How to handle the calibration program prior to
the actual calibration of each axis is detailed in
sections &DOLEUDWLRQ3HQGXOXP,,SURFHGXUH
RQ7386&SOXVRQSDJH and &DOLEUDWLRQ
3HQGXOXP,,SURFHGXUHRQ)OH[3HQGDQW,5&
RQSDJH.

&RQWLQXHVRQQH[WSDJH
40 3HAC 16578-1 Revision: E
 &DOLEUDWLRQ
3.2.3. Calibration, all axes, CalPend

&RQWLQXHG

 $FWLRQ 1RWH
6. Click 2..
A number of menus will flash by briefly
on the teach pendant unit, but no action
is required on behalf of the operator until
a specific action is displayed.
7. Confirm the position of all calibrated Detailed in section 3RVWFDOLEUDWLRQSURFHGXUH
axes when the calibration has been RQSDJH.
performed satisfactorily.
8. Disconnect all calibration equipment and
refit all protective covers.
Copyright 2003-2007 ABB. All rights reserved.

3HAC 16578-1 Revision: E 41

&DOLEUDWLRQ
3.2.4. Updating revolution counters

8SGDWLQJUHYROXWLRQFRXQWHUV

*HQHUDO
This section details how to perform a rough calibration of each robot axis, i.e. updating the
revolution counter value for each axis, using the pendant.

6WHS0DQXDOO\UXQQLQJWKHURERWWRWKHFDOLEUDWLRQSRVLWLRQ
This procedure details the first step when updating the revolution counter; manually running
the robot to the calibration position.
:$51,1*
Axis 4 has no mechanical limitation! Cabling inside the manipulator may be damaged if axis
4 is oriented incorrectly when performing calibration of the robot!

$FWLRQ 1RWH
1. Select axis-by-axis motion mode.
2. Jog the robot to place the FDOLEUDWLRQPDUNV Shown in section &DOLEUDWLRQVFDOHVDQG
within the tolerance zone. FRUUHFWD[LVSRVLWLRQRQSDJH.
IRB 140, 1400, 2400, 4400, 6600ID/
6650ID: Axes 5 and 6 must be positioned
together!
3. When all axes are positioned, store the Detailed in section:
revolution counter settings. 6WHS6WRULQJWKHUHYROXWLRQFRXQWHU
VHWWLQJZLWKWKH738RQSDJH
(RobotWare 4.0).
6WHS6WRULQJWKHUHYROXWLRQFRXQWHU
VHWWLQJZLWKWKH)OH[3HQGDQWRQSDJH
(RobotWare 5.0).

&RUUHFWFDOLEUDWLRQSRVLWLRQRID[LVDQG
When running the robot to calibration position, it is extremely important to make sure that
axes 4 and 6 of the below mentioned robots are positioned correctly. The axes can be

Copyright 2003-2007 ABB. All rights reserved.

calibrated at the wrong turn, resulting in wrong calibrated robot.
Make sure the axes are positioned according to the correct calibration values, not only
according to the calibration marks. The correct values are found on a label, located either on
the lower arm or underneath the flange plate on the base.
At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before
the revolution counters are updated.
If one of the below mentioned axes are rotated one or more turns from its calibration position
before updating the revolution counter, the correct calibration position will be lost due to
uneven gear ratio. This affects the following robots:

5RERWYDULDQW $[LV $[LV

IRB 140 Yes Yes
IRB 1600 No Yes
IRB 6400 / 200kg Yes No
IRB 6400R / 200kg Yes No
IRB 6600-175/2.55 Yes No
&RQWLQXHVRQQH[WSDJH
42 3HAC 16578-1 Revision: E
 &DOLEUDWLRQ
3.2.4. Updating revolution counters

&RQWLQXHG

5RERWYDULDQW $[LV $[LV

IRB 6600/6650 / others Yes Yes
IRB 6600ID/6650ID Yes No
IRB 6620 Yes No
IRB 6660 Yes Yes
IRB 7600 Yes Yes

If the calibration marks seem to be wrong (even if the motor calibration data is correct), try
to rotate the axis one turn, update the revolution counter and check the calibration marks
again (try both directions, if needed).

6WHS6WRULQJWKHUHYROXWLRQFRXQWHUVHWWLQJZLWKWKH738
This section details the second step when updating the revolution counter; storing the
revolution counter setting with the TPU (RobotWare 4.0).

 $FWLRQ 1RWH
1. Press the button "Miscellaneous" then ENTER to select the service
window.

xx0100000194

2. Select Calibration from the View menu.

The Calibration window appears.
If there is more than one unit connected to the robot, they will be listed
in the window.
Copyright 2003-2007 ABB. All rights reserved.

xx0100000201

&RQWLQXHVRQQH[WSDJH
3HAC 16578-1 Revision: E 43
&DOLEUDWLRQ
3.2.4. Updating revolution counters

&RQWLQXHG

 $FWLRQ 1RWH
3. Select the desired unit and choose Rev Counter Update from the
Calib menu.
The Revolution Counter Update window appears.

xx0100000202

4. Select the desired axis and press Incl to include it (it will be marked
with an x) or press All to select all axes.
5. Press OK when all axes that are to be updated are marked with an x.
CANCEL returns to the Calibration window.
6. Press OK again to confirm and start the update.
CANCEL returns to the Revolution Counter Update window.
7. At this point, it is UHFRPPHQGHG that the revolution counter values are Not required.
saved to a diskette.
8.

&$87,21
If a revolution counter is incorrectly updated, it will cause incorrect robot
positioning, which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
How to perform the check is detailed in section &KHFNLQJWKHFDOLEUDWLRQ
SRVLWLRQRQSDJH.
Copyright 2003-2007 ABB. All rights reserved.

6WHS6WRULQJWKHUHYROXWLRQFRXQWHUVHWWLQJZLWKWKH)OH[3HQGDQW
This procedure details the second step when updating the revolution counter; storing the
revolution counter setting with the FlexPendant (RobotWare 5.0).

$FWLRQ
1. On the $%% menu, tap &DOLEUDWLRQ.
All mechanical units connected to the system are shown along with their calibration
status.

&RQWLQXHVRQQH[WSDJH
44 3HAC 16578-1 Revision: E
 &DOLEUDWLRQ
3.2.4. Updating revolution counters

&RQWLQXHG

$FWLRQ
2. Tap the mechanical unit in question.
A screen is displayed: tap 5HY&RXQWHUV.

en0400000771

3. Tap 8SGDWH5HYROXWLRQ&RXQWHUV.
A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
Tap <HV to update the revolution counters.
Tap 1R to cancel updating the revolution counters.
Tapping <HV displays the axis selection window.
4. Select the axis to have its revolution counter updated by:
Ticking in the box to the left
Tapping 6HOHFWDOO to update all axes.
Copyright 2003-2007 ABB. All rights reserved.

Then tap 8SGDWH.

5. A dialog box is displayed, warning that the updating operation cannot be undone:
Tap 8SGDWH to proceed with updating the revolution counters.
Tap &DQFHO to cancel updating the revolution counters.
Tapping 8SGDWH updates the ticked revolution counters and removes the tick from the
list of axes.
6.

&$87,21
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning,
which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
See section &KHFNLQJWKHFDOLEUDWLRQSRVLWLRQRQSDJH.

3HAC 16578-1 Revision: E 45

&DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&DOLEUDWLRQVHQVRUPRXQWLQJSRVLWLRQV&DO3HQG

,QWURGXFWLRQ
This section specifies the mounting positions and directions of all calibration sensors on all
robot systems using Calibration Pendulum II.

5HPRYDORIHTXLSPHQW
Before fitting sensors to the robot:
Make sure that there is no cabling that could affect the position of the sensor!
Remove any position switches from axis 1. It is not possible to fit the sensor at the
reference position otherwise!
Additional information on calibration, alternative calibration positions etc, may be found in
the Product manual of the robot.

5HOHDVLQJRIFRPSUHVVHGVSULQJ
1RWH Release the compressed spring on the pendulum calibration tool after calibration of
axis 1. Also release the spring after calibration of axis 6 on IRB 260 and IRB 660.
Detailed instructions of how to compress/release the spring is given in section 3UHSDUDWLRQ
IRUXVLQJVHQVRURQD[HVDQG&DO3HQGRQSDJH.

,5%,5%
The illustrations below show the mounting positions and directions for both the reference
sensor and axis sensors on the robot. Notice that the pendulum is only fitted in one position
at a time! Notice also that the direction of the sensor is always the same, on each axis!

Reference position, IRB 140

Copyright 2003-2007 ABB. All rights reserved.

xx0200000244

A Calibration pendulum as reference sensor in reference position at base

&RQWLQXHVRQQH[WSDJH
46 3HAC 16578-1 Revision: E
 &DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

Reference position, IRB 1600

xx0500002490

A Calibration pendulum as reference sensor in reference position at base

Axis 1 IRB 140

Copyright 2003-2007 ABB. All rights reserved.

\xx0200000245

A Calibration pendulum as calibration sensor, axis 1

B Locating pin
C Calibration pendulum attachment screw

&RQWLQXHVRQQH[WSDJH
3HAC 16578-1 Revision: E 47
&DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

Axis 1, IRB 1600 and 1600ID

xx0500002491

A Calibration pendulum as calibration sensor, axis 1

B Locating pin
C Attachment screw

Axis 2, IRB 140

Copyright 2003-2007 ABB. All rights reserved.

xx0200000246

A Calibration pendulum as calibration sensor, axis 2

&RQWLQXHVRQQH[WSDJH
48 3HAC 16578-1 Revision: E
 &DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

Axis 2, IRB 1600/1600ID

xx0500002492

A Calibration pendulum as calibration sensor, axis 2

Axis 3, 4, 5 and 6, IRB 140, IRB 1600/1600ID

Copyright 2003-2007 ABB. All rights reserved.

xx0200000266

A Calibration pendulum as calibration sensor, axis 3

B Turning disk adapter
C Sensor locking screw
D Sensor cable, sensor B
E Sensor cable, sensor A

&RQWLQXHVRQQH[WSDJH
3HAC 16578-1 Revision: E 49
&DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

,5%
The illustrations below show the mounting positions and directions for both the reference
sensor and axis sensors on the robot. Notice that the pendulum is only fitted in one position
at a time (the same pendulum is used as both a reference and a calibration sensor).

Reference position IRB 1400

xx0200000248

A Calibration pendulum in reference sensor position

Axis 1 IRB 1400

Copyright 2003-2007 ABB. All rights reserved.

xx0200000249

A Calibration sensor, axis 1

B Locating pin
C Calibration pendulum attachment screw

&RQWLQXHVRQQH[WSDJH
50 3HAC 16578-1 Revision: E
 &DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

Axis 2 IRB 1400

xx0200000281

A Calibration sensor, axis 2

Axis 3, 4, 5 and 6 IRB 1400

Copyright 2003-2007 ABB. All rights reserved.

xx0200000266

A Calibration sensor
B Turning disk adapter
C Sensor locking screw
D Sensor cable, sensor B
E Sensor cable, sensor A

&RQWLQXHVRQQH[WSDJH
3HAC 16578-1 Revision: E 51
&DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

,5%,5%
The illustrations below show the mounting positions and directions for both the reference
sensor and axis sensors on the robot. Notice that the pendulum is only fitted in one position
at a time (the pendulum is used as both a reference and a calibration sensor)!

Reference position IRB 2400, IRB 260

xx0200000250

A Calibration pendulum in reference sensor position

Axis 1 IRB 2400, IRB 260

Copyright 2003-2007 ABB. All rights reserved.

xx0200000251

A Calibration sensor, axis 1

B Locating pin
C Calibration pendulum attachment screw

&RQWLQXHVRQQH[WSDJH
52 3HAC 16578-1 Revision: E
 &DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

Axis 2 IRB 2400, IRB 260

xx0200000280

A Calibration sensor, axis 2

Axis 3, 4, 5 and 6 IRB 2400

Copyright 2003-2007 ABB. All rights reserved.

xx0200000266

A Calibration sensor
B Turning disk adapter
C Sensor locking screw
D Sensor cable, sensor B
E Sensor cable, sensor A

&RQWLQXHVRQQH[WSDJH
3HAC 16578-1 Revision: E 53
&DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

Axis 3, IRB 260

xx0500002480

A Calibration sensor, axis 3 Copyright 2003-2007 ABB. All rights reserved.

&RQWLQXHVRQQH[WSDJH
54 3HAC 16578-1 Revision: E
 &DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

Axis 6, IRB 260

xx0500002481
Copyright 2003-2007 ABB. All rights reserved.

A Calibration sensor, axis 6

B Calibration bar, attached between the sensor and a ballplug on the robot
C Tapered attachment hole on the turning disk
D Ballplug where to attach the calibration bar
E 1RWH Make sure to fit the calibration bar at the extreme right of the sensor pin.

&RQWLQXHVRQQH[WSDJH
3HAC 16578-1 Revision: E 55
&DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

,5%,5%6
The illustrations below show the mounting positions and directions for both the reference
sensor and axis sensors on the robot. Notice that the pendulum is only fitted in one position
at a time (the pendulum is used as both a reference and a calibration sensor)!

Reference position IRB 4400, IRB 4450S

xx0200000252

A Calibration pendulum in reference sensor position

Axis 1 IRB 4400, IRB 4450S

Copyright 2003-2007 ABB. All rights reserved.

xx0200000253

A Calibration sensor, axis 1

B Locating pin
C Calibration pendulum attachment screw

&RQWLQXHVRQQH[WSDJH
56 3HAC 16578-1 Revision: E
 &DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

Axis 2 IRB 4400

xx0200000279

A Calibration sensor, axis 2

Axis 2, IRB 4450S

Copyright 2003-2007 ABB. All rights reserved.

xx0500002488

A Calibration sensor, axis 2

&RQWLQXHVRQQH[WSDJH
3HAC 16578-1 Revision: E 57
&DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

Axis 3, 4, 5 and 6 IRB 4400, IRB 4450S

xx0200000266

A Calibration sensor
B Turning disk adapter
C Locking screw
D Sensor cable, sensor B
E Sensor cable, sensor A

,5%
The illustrations below show the mounting positions and directions for both the reference
sensor and axis sensors on the robot

Reference position IRB 6600/6650, IRB 7600, IRB 660

Copyright 2003-2007 ABB. All rights reserved.

xx0200000183

A Calibration pendulum in reference sensor position. NOTE! The pendulum is only

fitted in one position at a time!

&RQWLQXHVRQQH[WSDJH
58 3HAC 16578-1 Revision: E
 &DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

Axis 1 IRB 6600/6650, IRB 7600, IRB 660

1RWH,IDQROGFDOLEUDWLRQSODWHIRUD[LVLVILWWHGWRWKHEDVHLWLVYLWDOWRFKDQJHLWWR
WKHQHZFDOLEUDWLRQSODWH+$&RUDWOHDVWWRUHPRYHLWGXULQJFDOLEUDWLRQ.

xx0400001107

1RWH,ISRVLWLRQEUHDNHUVDUHILWWHGIRUD[LVWKH\PXVWEHUHPRYHGEHIRUHXVHRIWKH
FDOLEUDWLRQSHQGXOXP+$&RQD[LV

xx0200000177

A Calibration pendulum. NOTE! The pendulum is only fitted in one position at a time!
Copyright 2003-2007 ABB. All rights reserved.

B Calibration pendulum attachment screw

C Locating pin

&RQWLQXHVRQQH[WSDJH
3HAC 16578-1 Revision: E 59
&DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

Axis 2 IRB 6600/6650, IRB 7600

xx0200000178

A Calibration pendulum, axis 2

Axis 2, IRB 660

Copyright 2003-2007 ABB. All rights reserved.

xx0500002475

A Calibration sensor, axis 2

&RQWLQXHVRQQH[WSDJH
60 3HAC 16578-1 Revision: E
 &DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

Axis 3-6 IRB 6600/6650, IRB 7600

A B C
xx0300000274

A Fit the Calibration Pendulum, screw home the attachment screw (by hand)
B Compress the spring and rotate the Calibration Pendulum counter clockwise
C At the end of the counter clockwise movement drop the Calibration Pendulum into its
calibration position

127(7RHQVXUHWKHUHVXOWRIWKHSURFHGXUHWREHDFFXUDWHLWLVYLWDOWKDWLWLVSHUIRUPHG
LGHQWLFDOO\HDFKWLPH
Copyright 2003-2007 ABB. All rights reserved.

&RQWLQXHVRQQH[WSDJH
3HAC 16578-1 Revision: E 61
&DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

Axis 3, IRB 660

xx0500002473

A Calibration sensor, axis 3

Copyright 2003-2007 ABB. All rights reserved.

&RQWLQXHVRQQH[WSDJH
62 3HAC 16578-1 Revision: E
 &DOLEUDWLRQ
3.2.5. Calibration sensor mounting positions, CalPend

&RQWLQXHG

Axis 6, IRB 660

Copyright 2003-2007 ABB. All rights reserved.

xx0500002474

A Calibration sensor, axis 6

B Calibration bar, attached between the sensor and a ballplug on the robot
C Tapered attachment hole on the turning disk
D 1RWH Make sure to fit the calibration bar at the extreme right of the sensor pin.

3HAC 16578-1 Revision: E 63

&DOLEUDWLRQ
3.2.6. Preparation for using sensor on axes 1 and 6, CalPend

3UHSDUDWLRQIRUXVLQJVHQVRURQD[HVDQG&DO3HQG

3UHSDUDWLRQRIFDOLEUDWLRQSHQGXOXP
The procedure below details the preparation of the calibration pendulum before calibration of
axis 1 on all robots and axis 1 and 6 on IRB 260 and IRB 660.

$FWLRQ ,OOXVWUDWLRQ
1. Compress the spring by moving
the inner hand wheel (axial A
movement)

xx0400001101

2. Rotate the inner hand wheel

clockwise on the shaft to lock the B
spring in compressed position.

Copyright 2003-2007 ABB. All rights reserved.

xx0400001102

3. After calibration of axis 1 (or axis

6 on IRB 260 and IRB 660),
release the compressed spring.

64 3HAC 16578-1 Revision: E

 &DOLEUDWLRQ
3.2.7. Calibration Pendulum II procedure on TPU, S4Cplus

&DOLEUDWLRQ3HQGXOXP,,SURFHGXUHRQ7386&SOXV

*HQHUDO
This section details how to use the Teach Pendant Unit (TPU) when calibrating the robot
using the Calibration Pendulum II (CalPend).

3URFHGXUHRQ738
The procedure below details how to perform the CalPend routine on the TPU.

 $FWLRQ ,OOXVWUDWLRQ
1. Press the "Program"
button on the TPU.

xx0300000009

2. Select "Special", and

then "Call service
routine".
3. Start the program: "Cal-
pendulum.rutin".
4. Select the required
calibration procedure
and press "START".
Copyright 2003-2007 ABB. All rights reserved.

xx0200000188

&RQWLQXHVRQQH[WSDJH
3HAC 16578-1 Revision: E 65
&DOLEUDWLRQ
3.2.7. Calibration Pendulum II procedure on TPU, S4Cplus

&RQWLQXHG

 $FWLRQ ,OOXVWUDWLRQ
5. Enter the value of your
choice, of which robot
axes to be calibrated.
Press 2..

xx0200000190

Default value: All axes

In this example, axis 1 was selected.
6. Press  to
acknowledge the
selection made.
Press 2..
7. Proceed to calibrate the Detailed in the calibration instructions for the robot axes.
individual robot axes.

Copyright 2003-2007 ABB. All rights reserved.

66 3HAC 16578-1 Revision: E

 &DOLEUDWLRQ
3.2.8. Calibration Pendulum II procedure on FlexPendant, IRC5

&DOLEUDWLRQ3HQGXOXP,,SURFHGXUHRQ)OH[3HQGDQW,5&

&DOLEUDWLRQ3HQGXOXP,,SURFHGXUH
The procedure below details how to use the FlexPendant when calibrating the robot using the
Calibration pendulum method.

$FWLRQ 1RWH
1. On the ABB menu tap Program Editor.
2. Tap on routines.
3. Select the Calpendulum routine.
4. Start the program by pressing START.
5. Selection of Production or Field Service Select Field Service Calibration, Production is
Calibration. only used in ABB:s prodution plant.
6. Selection of alternative positions for Used if you want to calibrate axes 1-2, with
axes 3-6. axes 3-6 in an alternative position.
7. Follow the further istructions on the Proceed to calibrate the individual robot axes,
FlexPendant. detailed in section &DOLEUDWLRQDOOD[HV
&DO3HQGRQSDJH.
Copyright 2003-2007 ABB. All rights reserved.

3HAC 16578-1 Revision: E 67

&DOLEUDWLRQ
3.2.9. Post calibration procedure

3RVWFDOLEUDWLRQSURFHGXUH

*HQHUDO
Perform the following procedure after calibrating DQ\ robot axis. The procedure is intended
to verify that all calibration positions are correct.

&KHFNLQJWKHFDOLEUDWLRQ
The procedure below details how to verify the calibration result.

 $FWLRQ 1RWH
1. Run the calibration home position program twice. Detailed in section &KHFNLQJ
Do not change the position of the robot axes after running WKHFDOLEUDWLRQSRVLWLRQRQ
the program! SDJH.
2. Check the calibration positions with help of the sensors as
described earlier for each axis.
IRB 6600, IRB 6650, IRB 6650S and IRB 7600: Check the
calibration positions of all axes. The acceptable
tolerances are:
axes 2-3: 0.20 mm/m
axes 4-6: 0.40 mm/m
IRB 140, IRB 1400, IRB 4400, IRB 6400R: Check the
calibration positions of axes 2, 5 and 6. If axes 5 and 6 are
within the tolerances given below, then axes 3 and 4 do
not need to be checked. The acceptable accuracy is:
IRB 4400, IRB 6400R: axes 2-3: 0.20 mm/m
IRB 4400, IRB 6400R: axes 4-6: 0.40 mm/m
IRB 140, IRB 1400: axes 2-3: 0.40 mm/m
IRB 140, IRB 1400: axes 4-6: 0.80 mm/m.
If the axes are outside the tolerance, start the calibration
procedure from the beginning, in increasing sequence of
the axes.
3. Repeat the check as above.
4. Adjust the FDOLEUDWLRQPDUNV when the calibration is done, Shown in section &DOLEUDWLRQ
if necessary. VFDOHVDQGFRUUHFWD[LV Copyright 2003-2007 ABB. All rights reserved.
SRVLWLRQRQSDJH.
5. The system parameters will be saved to the storage
memory at power off.
6. Change the values on a new label and stick it on top of the
label located:
IRB 140, IRB 6600, IRB 6650, IRB 6650S, IRB
7600, IRB 6400R: on the lower arm.
IRB 1400, IRB 2400, IRB 4400: underneath the
flange plate on the base.
IRB 260: on the back of the frame.
IRB 940: on one side of the upper platform.
7. Remove any calibration equipment from the robot.

68 3HAC 16578-1 Revision: E

 &DOLEUDWLRQ
3.2.10. Checking the calibration position

&KHFNLQJWKHFDOLEUDWLRQSRVLWLRQ

*HQHUDO
Check the calibration position before beginning any programming of the robot system. This
may be done in one of two ways:
Using a MoveAbsJ instruction with argument zero on all axes.
Using the Jogging window on the teach pendant.

8VLQJD0RYH$EV-LQVWUXFWLRQRQWKH7386&SOXV
This section describes how to create a program, which runs all the robot axes to their zero
position

$FWLRQ 1RWH
1. Create a new program.
2. Use MoveAbsJ.
3. Create the following program: MoveAbsJ
[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,
9E9]]\NoEOffs, v1000, z50, Tool0
4. Run the program in manual mode.
5. Check that the calibration marks for the axes align The calibration marks are shown in
correctly. If they do not, update the revolution section &DOLEUDWLRQVFDOHVDQG
counters! FRUUHFWD[LVSRVLWLRQRQSDJH.
How to update the revolution
counters is detailed in section
8SGDWLQJUHYROXWLRQFRXQWHUVRQ
SDJH
6. Check that the positions of axes 1-2-3 are reached Detailed in section 8SGDWLQJ
and that the calibration marks on axes 4-5-6 are UHYROXWLRQFRXQWHUVRQSDJH.
aligned correctly.
If they are not, update the revolution counters!

8VLQJD0RYH$EV-LQVWUXFWLRQRQWKH)OH[3HQGDQW,5&
Copyright 2003-2007 ABB. All rights reserved.

This section describes how to create a program, which runs all the robot axes to their zero
position.

 $FWLRQ 1RWH
1. On ABB menu tap Program Editor.
2. Create a new program.
3. Use MoveAbsJ in the Motion&Proc menu.
4. Create the following program: MoveAbsJ
[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,
9E9]]\NoEOffs, v1000, z50, Tool0
5. Run the program in manual mode.

&RQWLQXHVRQQH[WSDJH
3HAC 16578-1 Revision: E 69
&DOLEUDWLRQ
3.2.10. Checking the calibration position

&RQWLQXHG

 $FWLRQ 1RWH
6. Check that the calibration marks for the axes align The calibration marks are shown in
correctly. If they do not, update the revolution section &DOLEUDWLRQVFDOHVDQG
counters! FRUUHFWD[LVSRVLWLRQRQSDJH.
How to update the revolution
counters is detailed in section
8SGDWLQJUHYROXWLRQFRXQWHUVRQ
SDJH.
7. Check that the positions of axes 1-2-3 are Detailed in section 8SGDWLQJ
reached and that the calibration marks on axes 4- UHYROXWLRQFRXQWHUVRQSDJH.
5-6 are aligned correctly.
If they are not, update the revolution counters!

8VLQJWKH-RJJLQJZLQGRZRQWKH7386&SOXV
This section describes how to jog the robot to all axes zero position.

 $FWLRQ ,OOXVWUDWLRQ1RWH
1. Open the Jogging window.

xx0100000195

2. Choose running axes-by-axes.

xx0100000196

3. Manually run the robot axes to a position where the

axis position value read on the TPU, is equal to zero.
4. Check that the FDOLEUDWLRQPDUNV for the axes align The calibration marks are
correctly. If they do not, XSGDWHWKHUHYROXWLRQFRXQWHUV! shown in section &DOLEUDWLRQ
Check that the positions of axes 1-2-3 are reached and VFDOHVDQGFRUUHFWD[LVSRVLWLRQ
that the calibration marks on axes 4-5-6 are aligned RQSDJH.
correctly. Detailed in section 8SGDWLQJ
If they are not, XSGDWHWKHUHYROXWLRQFRXQWHUV! UHYROXWLRQFRXQWHUVRQSDJH.
Copyright 2003-2007 ABB. All rights reserved.

8VLQJWKH-RJJLQJZLQGRZRQWKH)OH[3HQGDQW,5&
This section describes how to jog the robot to all axes zero position.

$FWLRQ 1RWH
1. Tap Jogging in the ABB menu.
2. Tap Motion mode to choose group of axes to jog.
3. Tap axes 1-3 to jog axes 1, 2 or 3.
4. Manually run the robots axes to a position where the axis
position value read on the FlexPendant, is equal to zero.

&RQWLQXHVRQQH[WSDJH
70 3HAC 16578-1 Revision: E
 &DOLEUDWLRQ
3.2.10. Checking the calibration position

&RQWLQXHG

$FWLRQ 1RWH
5. Check that the calibration marks for the axes align The calibration marks are
correctly. If they do not, update the revolution counters! shown in section &DOLEUDWLRQ
VFDOHVDQGFRUUHFWD[LV
SRVLWLRQRQSDJH.
How to update the counters
is detailed in section
8SGDWLQJUHYROXWLRQFRXQWHUV
RQSDJH.
6. Check that the positions of axes 1-2-3 are reached and Detailed in section 8SGDWLQJ
that the calibration marks on axes 4-5-6 are aligned UHYROXWLRQFRXQWHUVRQSDJH
correctly. .
If they are not, update the revolution counters!
Copyright 2003-2007 ABB. All rights reserved.

3HAC 16578-1 Revision: E 71

&DOLEUDWLRQ
3.3.1. About Reference Calibration

5HIHUHQFH&DOLEUDWLRQ

$ERXW5HIHUHQFH&DOLEUDWLRQ

8VDJHRI5HIHUHQFH&DOLEUDWLRQ
The Reference Calibration is used in field, to restore the robot home position, eg. after service
activities. (Reference Calibration is a function included in the service routine Calibration
Pendulum.)

7KHSULQFLSOHRI5HIHUHQFH&DOLEUDWLRQ
The calibration procedure is based on reference values that are defined once and then used
each time the robot needs to be recalibrated. The values are stored on the controller, with a
file name equal to the serial number of the robot.
The reference values must be defined before required use of robot recalibration.

3HULSKHUDOHTXLSPHQWDQGURERWSRVLWLRQ
Tools and process cabling are allowed on the robot. Reference Calibration will also function
for both floor mounted and hanging robots.
As for the robot position, the axes 2-6 are set to 0, while the position of axis 1 has no
significance but can instead be set to whatever suits best for the installation site.

/LPLWDWLRQV
The Reference Calibration routine has following limitations:
calibration of axis 1 must be performed with Calibration Pendulum II.
the axes of a back bending robot are divided into two groups: axes 2, 3, 5 and axes 4,
6. Parallel rod robots have their own calibration reference for axis 2 on the lower arm,
which results in the grouping 2 and 3, 5 and 4, 6 instead. Reference Calibration can
only be used for one axis from each group at the same occassion. Calibration is
consequently not possible for several axes within the same group. If service activities

Copyright 2003-2007 ABB. All rights reserved.

are performed for several axes within the same group, the service must be divided into
sessions with calibration in between.

:KLFKURERWV\VWHPVFDQEHFDOLEUDWHGZLWK5HIHUHQFH&DOLEUDWLRQ"
The integrated software for Reference Calibration is developed for RobotWare 5.07 and later.
For RobotWare 4.0 and earlier releases of 5.0, standalone versions are available with manual
operation, detailed in separate documentation enclosed with the release.

5HTXLUHGWRROV
The required tools for Reference Calibration are specified in section (TXLSPHQWIRU
FDOLEUDWLRQSHQGXOXPRQSDJH.

72 3HAC 16578-1 Revision: E

 &DOLEUDWLRQ
3.3.2. Preparation of reference surface at tool

3UHSDUDWLRQRIUHIHUHQFHVXUIDFHDWWRRO

*HQHUDO
In order to perform Reference Calibration the robot needs to be prepared with a reference
surface (adapter) for fitting the calibration pendulum housing on the tool.
This section details how to prepare the reference surface.

5HIHUHQFHDGDSWHUVKRXOGVWD\ILWWHGSHUPDQHQWO\
The reference adapter should be permanently fitted and never removed after obtaining the
reference values. If the reference surface is temporary, it is critical to be able to refit the
adapter with high accuracy once its going to be used for calibration after service. The
inaccurancy of refitting the adapter will have negative impact on the calibration procedure.

+DQJLQJURERWV
Prepare the reference surface in the same way for hanging robots as for floor mounted. The
reference sensor will be upside down and all the measurements are taken upside down.

5HTXLUHGHTXLSPHQW

(TXLSPHQW $UWQR 1RWH

Reference adapter 3HAC 025397-001

3UHSDUDWLRQRIUHIHUHQFHVXUIDFH
The procedure below details how to prepare the reference surface for the reference sensor.

$FWLRQ 1RWH
1.

127(
In order to achieve high accuracy, the
Copyright 2003-2007 ABB. All rights reserved.

reference surface should be fitted

permanently to the robot. Any removal and
refitting once the reference values are defined
increases inaccuracy and has a negative
impact on the calibration performance!
2. Choose an appropriate location for the The mounting location must be:
reference surface on the tool. horizontal 5, when robot is
standing in calibration position.
perpendicular to the tool flange
surface 5 (to be mounted in
one of four directions, in steps
of 90).
3. Use the UHIHUHQFHDGDSWHU as a drilling pattern Art. no. is specified in 5HTXLUHG
and mark where to drill the four holes on the HTXLSPHQWRQSDJH.
chosen mounting location.
4. Drill the two holes matching the M8 screws to
a depth of 10 mm.
Cut the thread M8.

&RQWLQXHVRQQH[WSDJH
3HAC 16578-1 Revision: E 73
&DOLEUDWLRQ
3.3.2. Preparation of reference surface at tool

&RQWLQXHG

$FWLRQ 1RWH
5. Drill the two remaining holes ( 6 mm) to a
depth of minimum 5 mm.
6. Fit the reference adapter using the two M8
screws and the two guiding pins included with
the adapter.

Copyright 2003-2007 ABB. All rights reserved.

74 3HAC 16578-1 Revision: E

 &DOLEUDWLRQ
3.3.3. Defining reference values for calibration of axes 2-6

'HILQLQJUHIHUHQFHYDOXHVIRUFDOLEUDWLRQRID[HV

*HQHUDO
In order to perform Reference Calibration, reference values must first be defined and stored
to the robot system. This must be done before recalibration is required.
This section details how to define these reference values for the robot system. The values are
then used each time the robot needs to be recalibrated.

'HILQLQJUHIHUHQFHYDOXHV
The definition of reference values is made once and the values are then stored to the robot
system.
The procedure of defining the reference values differs some between bending backwards and
parallel rod robots. Differences are pointed out in the procedure.

$FWLRQ 1RWH
1. Make sure the robot is prepared for the
procedure. (i.e. all service or installation
activities are completed and the robot is
ready to run.)
2. Check that all required hardware is Detailed in section (TXLSPHQWIRUFDOLEUDWLRQ
available for calibrating the robot. SHQGXOXPRQSDJH.
3. Remove any mechanical equipment
that might stop the calibration
movements, eg. mechanical stops on
axis 1.
4. Prepare the reference surface at the Detailed in section 3UHSDUDWLRQRIUHIHUHQFH
tool. VXUIDFHDWWRRORQSDJH.
5. Run the robot to the desired position 1RWH The position set for axis 1 at this point
regarding axis 1. Move axes 2-6 close determines also the future position of the axis
to zero degrees. at each occasion of recalibration.
Copyright 2003-2007 ABB. All rights reserved.

&RQWLQXHVRQQH[WSDJH
3HAC 16578-1 Revision: E 75
&DOLEUDWLRQ
3.3.3. Defining reference values for calibration of axes 2-6

&RQWLQXHG

$FWLRQ 1RWH
6. Prepare and clean the reference Reference surfaces for bending backward
surfaces to be used. robots (IRB 1600, 6600, 6650, 6650S, 7600):
Clean with isopropanol.

xx0500002470

Reference surfaces for parallel rod robots

(IRB 140, 1400, 2400, 260, 4400, 4450S,
660):

xx0500002471

A. Reference surface at the tool.

Preparation is detailed in section
Copyright 2003-2007 ABB. All rights reserved.
3UHSDUDWLRQRIUHIHUHQFHVXUIDFHDW
WRRORQSDJH.
B. Reference surface at base.
C. Reference surface of axis 2.
7. Run the service routine CalPendulum The program will guide the operator through
from the FlexPendant and choose the complete procedure, giving information of
Reference Calibration. If there are no each step to perform. Follow the steps in the
reference values set for the robot, the program carefully.
program senses it and requires to How to run a service routine from the
define these. FlexPendant is detailed in the 2SHUDWLQJ
:DUQLQJ The robot will automatically PDQXDO,5&ZLWK)OH[3HQGDQW.
move to the calibration position,
keeping the manually set axis 1 position
and setting axes 2-6 to zero.

&RQWLQXHVRQQH[WSDJH
76 3HAC 16578-1 Revision: E
 &DOLEUDWLRQ
3.3.3. Defining reference values for calibration of axes 2-6

&RQWLQXHG

$FWLRQ 1RWH
8. Make notes or take pictures that shows
following conditions under which the
reference values were taken:
position and alignment of the
calibration pendulum housing at
the reference surface on the tool
(allowed to be fitted in one of
four directions, in steps of 90)
position of axis 1
tools and/or dresspack mounted
on the robot.
The information is valuable at future
service occassions in order to get
highest accuracy possible from the
recalibration.
9. Remove the calibration tools from the
robot and refit the covers to the
reference surfaces.
10. Restore the robot for production.

6WRUDJHRIUHIHUHQFHYDOXHV
The reference values are automatically stored on the controller, as a file named equally to the
serial number of the robot. The file is stored in the Home folder.
Copyright 2003-2007 ABB. All rights reserved.

3HAC 16578-1 Revision: E 77

&DOLEUDWLRQ
3.3.4. Preparing the calibration procedure, RefCal

3UHSDULQJWKHFDOLEUDWLRQSURFHGXUH5HI&DO

*HQHUDO
This section details all required preparations for performing Reference Calibration (RefCal).

3UHSDUHWKHFDOLEUDWLRQSURFHGXUH
The procedure below details how to prepare the calibration procedure.

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1.

127(
In order to perform Reference Calibration,
reference values must have been defined and
stored to the robot system prior to the
calibration occasion! If no values are
available, the robot must be calibrated with
Pendulum Calibration II instead.
2. Make sure the robot is prepared for calibra-
tion. (i.e. all service or installation activities are
completed and the robot is ready to run.)
3. Check that all required hardware is available Specified in section (TXLSPHQWIRU
for calibrating the robot. FDOLEUDWLRQSHQGXOXPRQSDJH.
4. Connect the calibration equipment to the robot Specified in section 6WDUWXSRI
controller and start up the Levelmeter 2000. /HYHOPHWHURQSDJH.
5. It is recommended that the reference adapter Detailed in section 3UHSDUDWLRQRI
should be permanently fitted to the tool when UHIHUHQFHVXUIDFHDWWRRORQSDJH.
defining the reference values, in order to
achieve accurate values during calibration.
If the adapter is missing anyhow, it must be
fitted as detailed in section 3UHSDUDWLRQRI
UHIHUHQFHVXUIDFHDWWRRORQSDJH.
6. Remove any mechanical equipment that
might stop the calibration movements, eg. Copyright 2003-2007 ABB. All rights reserved.
mechanical stops on axis 1.

&RQWLQXHVRQQH[WSDJH
78 3HAC 16578-1 Revision: E
 &DOLEUDWLRQ
3.3.4. Preparing the calibration procedure, RefCal

&RQWLQXHG

$FWLRQ 1RWH
7. Remove all the covers from the reference Reference surfaces for bending
surfaces and clean them with isopropanol. backward robots (IRB 1600, 6600,
6650, 6650S, 7600):

xx0500002471

Reference surfaces for parallel rod

robots (IRB 140, 1400, 2400, 4400,
4450S):

xx0500002471

A. Reference surface at the tool.

Copyright 2003-2007 ABB. All rights reserved.

B. Reference surface at the base.

C. Reference surface of axis 2.
8. Calibrate the robot. Detailed in section &DOLEUDWLRQRID[HV
XVLQJSUHGHILQHGUHIHUHQFHYDOXHV
RQSDJH.

3HAC 16578-1 Revision: E 79

&DOLEUDWLRQ
3.3.5. Calibration of axes 2-6 using predefined reference values

&DOLEUDWLRQRID[HVXVLQJSUHGHILQHGUHIHUHQFHYDOXHV

*HQHUDO
The calibration procedure requires previously defined reference values. If there are no
reference values stored in the robot system at the occassion of the calibration, Reference
Calibration is not possible. Calibrate the robot using Calibration Pendulum II instead.

&DOLEUDWLRQVHTXHQFH
The program will ask for what axis to calibrate. Reference calibration can only be used for
one axis from each of the groups 2, 3, 5 and 4, 6. The program will automatically run the
correct sequence in order to get the correct accuracy. Axis 4 will always be run four times and
axis 5 will always be run three times.
If two axes have been chosen, these will be run in a double sequence eg. 5, 6, 5, 6.
It is recommended to use automatic fine calibration instead of manual.

&DOLEUDWLRQSURFHGXUH5HIHUHQFH&DOLEUDWLRQ
The procedure below details how to calibrate the robot system with Reference Calibration.

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1. Read the limitations in Reference Calibration. Detailed in section /LPLWDWLRQVRQSDJH
.
2. Prepare the calibration as detailed in section
3UHSDULQJWKHFDOLEUDWLRQSURFHGXUH5HI&DORQ
SDJH.
3. Perform a fine calibration of the axis that has
been serviced.
4. Jog the robot close to the defined position There should be notes or pictures taken
regarding axis 1. during definition of the reference values
Data about the position is stored in the file that that shows the position of axis 1.
contains the reference values and will be used
later on in the calibration procedure, but the

Copyright 2003-2007 ABB. All rights reserved.

axis should be moved as close as possible to
the defined position in order to prevent large
movement of the axis later on.
5. Jog axes 2-6 close to zero degrees.
6. Run the service routine CalPendulum from the The program will guide the operator
FlexPendant and choose Reference Calibra- through the complete procedure, giving
tion. information of each step to perform.
:DUQLQJ The robot will move automatically to Follow the steps in the program
the calibration position and will use the values carefully.
for axis 1 positioning from the reference file. How to run a service routine from the
FlexPendant is detailed in the 2SHUDWLQJ
PDQXDO,5&ZLWK)OH[3HQGDQW.
7. After ending the program, remove all the
calibration tools and refit the covers to the
reference surfaces.
8. Restore the robot for production.

80 3HAC 16578-1 Revision: E

 ,QGH[

& preparing
calibrating Calibration Pendulum II procedure 39
roughly 42 Reference Calibration procedure 78
sensors 32 reference surface at tool 73
with Calibration Pendulum II 40 sensor axes 1 and 6 64
with Reference Calibration 80 5
calibration
Reference Calibration
Calibration Pendulum II 9, 38
defining values 75
marks/scales 10
equipment on robot 72
position of sensor 46
limitations 72
Reference Calibration 9, 72
method 72
robot home calibration 9
sequence 80
rough 42
reference surface at tool 73
sequence, CalPend 40
revolution counters
sequence, RefCal 80
memory is lost 8
tools 26
storing on FlexPendant 44
verification 68
storing on TPU 43
when to calibrate 8
updating 42
which robots 7
robot position 10
Calibration Pendulum II
equipment on robot 38 6
method 38 scales on robot 10
preparation 39 sensor
sequence 40 calibrating 32
calibration position 42 checking 34
checking 69 directions 46
jogging to, FlexPendant 70 mounting locations 46
jogging to, TPU 70 preparation for axes 1 and 6 64
scales 10 storage 28
changed resolver values 8 sequence
' CalPend 40
RefCal 80
defining values, RefCal 75
storage of sensor 28
( sync marks 10
equipment on robot 7
Calibration Pendulum II 38
tools 26
Reference Calibration 72
start up 30
) storage 28
Copyright 2003-2007 ABB. All rights reserved.

FlexPendant turning disk adapter 27

calibration procedure, CalPend 67 warm up 28
jogging to calibration position 70 TPU
MoveAbsJ instruction 69 calibration procedure, CalPend 65
updating revolution counters 44 jogging to calibration position 70
MoveAbsJ instruction 69
/ updating revolution counters 43
Levelmeter 2000 turning disk adapter 27
connections 30 8
power 31
settings 30 updating revolution counters 42
start up 30
0
MoveAbsJ instruction
FlexPendant 69
TPU 69
3
pendulum. See sensor.
position, robot 10

3HAC 16578-1 Revision: E 81

82
,QGH[

3HAC 16578-1 Revision: E

Copyright 2003-2007 ABB. All rights reserved.
 3HAC 16578-1, Revision E, en

ABB Robotics
S-721 68 VSTERS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592