Copyrights

CAUTION
Do not perform any work covered in this manual until you have read and understand completely each
step in the procedure. Ensure that all Locked-out / Tag procedures are followed before performing
any work on any system.
NOTE:
The information contained in this manual is subject to change without notice and should not be
construed as a commitment by ABB Inc. ABB Inc. assumes no responsibility for any errors / changes
that may not appear in this manual.

In no event shall ABB Inc. be liable for incidental or consequential damages arising from the use of
this manual, or of the software and / or hardware described in this manual.

The material in this manual must not be reproduced or copied in whole or in part without the written
permission of ABB Inc. The contents of this manual must not be imparted to a third party nor be used
for any unauthorized purpose. Contravention will be prosecuted to the full extent of the law.

Additional copies of this manual can only be obtained with permission from ABB Inc. Training

© Copyright 2005 ABB

All Rights Reserved

ABB Robotics MYRO Training Centres

INTRODUCTION

1
Course Objectives
Upon completion of this course the student will be able to
successfully:

Practice safety as it pertains to the robot system.

Identify and use the Flex Pendant.
Run the robot system in manual mode and automatic mode.
Interpret and respond to event messages.
Load, save, and edit basic programs using the Flex Pendant.
Modifying movement instructions in a basic program.
Understand the use of input and output instructions in a basic program.
Manually manipulate I/O to release and activate tooling.
Create and Define a tool center point, using the 4 point method

Course Objectives
Upon completion of this course the student will be able to
successfully:

Use movement instructions in a basic program.

Use input and output instructions in a basic program.
Create routines, and use routine instructions in a basic program.
Use Offsets for movement instructions.
Use work objects for position reference.
Understand and update Revolution Counters.

2
Course Content
Section Description
1 Introduction
2 Safety
3 System Description
4 Coordinate& Jogging
5 Basic Programming
6 Backup and Restore
7 Structured Programming
8 Event Messages

ABB Robotics MYRO Training Centres

SAFETY

3
Introduction

Students participating in courses arranged by ABB

need to have knowledge about safety procedures
from the Operator’s Manual and Product Manual.
In addition to instructor information, students should
study the manuals. They must acknowledge the
understanding of safety procedures and how to work
with robots on the training premises.

Safety Solutions – an Overview

Pinch Points
Lock Outs
Emergency stop
Operating mode
Auto
Manual < 250 mm/s
Manual 100% (Option)

Enabling device
Enabling device
(Dead mans grip)
Hold-to-run
Hold-to-run buttons
Safeguard stop
(Auto and Manual) (for left or right hand)

Limiting the workspace

4
Accident Risks

Always avoid PINCH POINTS

Fault tracing
Repair
Change of program
Test run

LOCK OUT
Use Lock out Devices.

5
Emergency Stop

Built in emergency stop pushbuttons are

found both on the FlexPendant and
Control module standard.
Extra emergency stops can be connected to
the robot systems safety chain.

Recover by resetting pushbutton and

pressing the Motors On button.

Operating Mode

Automatic mode
Production mode (no speed limit)
Manual mode
< 250 mm/s – max velocity 250 mm/s
100 % – Option, robot can be jogged/tested with
no speed limit.

6
Enabling Device (Dead Mans Grip)
The enabling device is a press switch with three positions
The switch must be in the middle positions in order to
activate the motors
All robot movement will immediately stop if the switch is
released or pressed to the bottom

Enabling device

Hold-to-Run

Option (this function can be activated in the parameters for manual

reduced speed mode)
The enabling device and one of the hold-to-run buttons must be
pressed simultaneously to start the motors

Enabling device

Hold-to-run buttons
(for left or right hand)

7
Version 2 FlexPendant Hold-to-Run

Hold-to-Run buttons and

prompt message removed

Hold down the play key, to run the program

Hold down the FWD or BWD key to step through program

Release the pressed key to stop execution

Safeguard Stop

The connection of safeguard stop enables inter-locking of external safety

equipment, such as: doors, photo-electric trip device, photo cells or sensible
mats
There are two categories of Safeguard stop:
Manual – the safeguard stop is active regardless of operating modes
(Emergency Stop, General Stop, Superior Stop)
Auto – the safeguard is active when automatic mode is selected (Auto Stop)
It is possible to activate Delayed Safeguard Stop.
A delayed stop gives a smooth stop. The robot stops in the same way as at a
normal program stop with no deviation from the programmed path. After
approx. 1 second the power supplied to the motors shuts off.

8
Limiting the Workspace

To avoid the risk of getting caught between the

robot and the perimeter safty equipment, e.g.
a fence, the robot’s workspace can be
limited:
All axis can be software limited
On some robots Axis 1–3 can be limited by
adjustable mechanical stops and
controlled by limit switches

Safety Regarding Grip Device

All grip devices should be designed so the work piece will be

held even on power failure and other disturbances in the
robot system
There should be possibilities to release the work piece
manually

9
Electrical Safety

Hazardous power in both the cabinet and the robot

Control Module
Power supply – 230 VAC
Customer equipment – …
Drive Module
Power Source – 480 VAC
Power supply – 230 VAC
Power supply to robot motors – 370VDC up to 700 VDC

Safety Regarding Releasing the Breaks

The brakes on the robot motors can be manually released.

Before the brakes are released, be sure the weight of the robot arm is supported
to avoid robot arm falling and doing damage to equipment or people.

10
Personal Safety

Control the robots maximum work space

You may have to move the table to get a safe area outside
the robots work space, in order to minimize the risk for
personal contact with the robot

ABB Robotics MYRO Training Centres

SYSTEM DESCRIPTION

11
Robot System

Panel Mount
Dual Controller

Compact Controller Single Controller

IRC5 Controller Types Robot Manipulator

ABB Robot Family

Product Range

Model Specification
Robot model IRB120 IRB140 IRB1600 IRB2400 IRB2600 IRB4400 IRB4600 IRB6700 IRB7600
Payload [kg] 3 6 6 - 10 12 - 20 12 - 20 60 20 - 60 200 - 300 150 - 500
Reach [m] 0.58 0.81 1.20 - 1.45 1.55 1.65 - 1.85 1.96 2.05 - 2.55 2.60 - 3.20 2.30 - 3.50
No. of Axis 6 6 6 6 6 6 6 6 6

Robot model IRB260 IRB460 IRB660 IRB760 IRB360 IRB6620LX IRB52

Payload [kg] 30 110 180 - 250 450 1-8 150 7
Reach [m] 1.50 2.40 3.15 3.18 1.13 - 1.60 1.90 1.20 - 1.45
No. of Axis 4 4 4 4 3 (4) 6 6
ABB Robotics

12
System Description
FlexPendant

RobotStudio

Main power switches

Control Module

Drive Module

IRC5 Single Cabinet Outside

Main Disconnect

E-Stop

Motors On

Mode Selector

Run Chain Status

USB Port
Ethernet Service

Hour Meter

13
 IRC5 Compact (Controller Overview)

Manipulator Connectors
Presently not used FlexPendant
connector

Brake
Release
(IRB120 only)

Presently not used

Main Switch

Main Power Customer 24 V Safety DeviceNetTM Lean Main Computer front with
Connector Operator´s Panel For external I/O units CF memory, ports and PCI slots
Digital I/O

IRC5 Single Cabinet (Controller Overview)

Main Computer
Unit

Compact Flash
mass memory

Panel
Unit

Main Computer

UltraCap
Field bus
adapter:
Power Supply Ethernet
Main Drive I/PTM
Unit
Hot Plug (option) PROFIB
US DP
PROFIN
ET IO
Additional Drive Axis Computer
Unit

Front connectors I/O units or PLC

behind cover

14
Example of an Industrial Robot – IRB 6700

Example of an Industrial Robot – IRB 140

15
Example of an Industrial Robot – IRB 360

4 Hard keys for fast access

IRC5 – FlexPendant Programmable

Graphical color touch screen

3-way Joy Stick

Joy Stick
Control buttons

4 Hard keys for running programs

Start
Execute Backward/Forward
Stop program

16
IRC5 – FlexPendant
ABB Menu Status bar

Main menu

Windows style
“switch between Quickset Menu
open windows/views”

IRC5 – FlexPendant
ABB Main Menu

17
Quickset button
The Quickset Button provides quick access to change properties for the following
functions or items:

Mechanical Unit
Increment
Run Mode
Step Mode
Speed
Tasks

Tap on the Quickset Icon to display

the menus. Tap on it again to close
the view.

Quickset Menu Description

Mechanical Unit: A feature that allows the handler to choose between the robot
and the motion modes for the robot and external axis, this is also where you can
choose the coordinates and active tool, and active work object.

When multiple Robots are on a

system, the Blue Box indicates the
current selection.

18
Quickset Menu Description
Show/Hide Details: By Tapping on the Show Details button, your current selections
can be viewed. The button will change back to Hide Details if hit again allowing you
to minimize that screen.

The selected Coordinate system,

and Motion Mode setting is
displayed when Show Details is
pressed. Tap on one of the other
selections to change that property.

Quickset Menu Description

Step Mode: Selecting the different Step Mode features allows you to define how the
Step-by-Step program execution will function.

Step Into: Steps into called routines

and executes them step-by-step.
Step Out: Executes the remains of
the current routine and then stops at
the next instruction in the routine
from which the current routine was
called.
Step Over: Called routines are
executed in one single step.
Next Move: Steps to the next move
instruction. Stops before and after
movement instructions, for example
to modify positions.

19
Quickset Menu Description
Speed: The Speed settings apply to the current Operating Mode. But, if you
decrease the speed in Automatic Mode, the setting also applies to Manual mode if
you change back to that mode. The current running Speed, in relation to Max, is
displayed above the buttons.

-1% & +1%: Decrease & Increase

running speed in steps of 1%.

-5% & +5%: Decrease & Increase

running speed in steps of 5%.

25%: Run at quarter speed (25%).

50%: Run at half speed (50%).

100%: Run at full speed (100%).

Quickset Menu Description

Tasks: If you have the option Multitasking installed there can be more than one Task.
Otherwise there is only one Task. By default, only normal Tasks are possible to
activate/deactivate in the Quickset menu. Using the Control Panel you can however
change the settings so all Tasks are possible to activate & deactivate.
Activated tasks are started and stopped with the Start and Stop buttons on the
FlexPendant.

The green checkmark indicates

which Task is selected.

20
 Exercise

1. Go to your assigned robots and practice jogging the robot

using the Quick Set button and the joystick.

2. What happens when you press the top center box on the
FlexPendant?

3. Look at the Event Log. What was the last event that
occurred?

4. Challenge: Find and Change the FlexPendant display

Brightness and contrast.

5. Challenge: Find and Change the FlexPendant for either

Right or Left handed users.

6. Practice pressing buttons on the FlexPendant. If you have

any questions ask the instructor.

ABB Robotics MYRO Training Centres

JOGGING & COORDINATE

SYSTEM

21
Jogging the robot

Basic Setting for jogging

Select Mechanical Unit
Select Motion Mode
Select Coordinate System
Select Tool
Select Work Object

Jogging the robot

Remember that the joystick assumes you are facing the front of the robot.

22
Jogging the robot

6 Axis Robot

Axis 3

Axis 4
Axis 2

Axis 1

23
4 Axis Robot (FlexPalletiser)

3 / 4 Axis Robot (FlexPicker)

24
Jogging robot Axis

Major Axes
1,2,3
Minor Axes
4,5,6

Joystick directions (+)

Jogging along Coordinate axis

Linear

Orientation

Joystick directions (+)

25
Hard Motion Keys

Mechanical Unit
Linear / Reorient
Group 1 / Group 2 Axis
Activate last used increment

Jogging External Axis Track

26
Jogging External Axis Positioner

Incremental Jogging
Greater jogging control with Incremental steps.

27
Jogging collisions

Disabling Jog supervision allows robot to be jogged after collision

Software option, ‘Collision Detection’ (613-1), required for this
Path supervision is not effected only jogging
Try before releasing brakes

Disabled

Jogging Override Speed

Used when the default 100% value feels to sensitive

Value can be set to a percentage of the default jog speed
Reduce percentage will be slower and less sensitive
Jog speed is still proportional to joystick deflection

28
Jogging Window

Jogging the robot

+3 +4
-5
+6

-2
-3
-4 +5 -6
+2
+5
+2
-1 +1
-4 +4
-1 +1
+6 -6
+3 -3
-5
-2

+Z Z
Y
+Y
-X
-X
X
-Y +Y
-Y +Y
+Z -Z
+Z -Z +X
+X
+X

29
Coordinate Systems
TCP Z
Y
X
Tool coordinates

Z Z
Y Y

X WorkObject
Base coordinates
X
Z
Y

X
World coordinates

Right Hand Rule

The Right Hand Rule applies to all coordinate systems

+Z

+X

+Y Tool

+Z
+X
WorkObject
+Y

+Z
+X
Base
+Z +Y
+X
World
+Y

30
Tool Coordinate System
Tool coordinate system

Tool coordinates
Y
Tool0

X Z

Z
Y

Base coordinates

Coordinate System
Different examples of tools and TCPs.

TCP
TCP

TCP

TOOL0
TCP

Tool0 is always the

ref.point for the other tools

31
Work Object Coordinate System

User Coordinate System

Object Coordinate System Z
Y

TCP Z WorkObject
Y
X X
Tool coordinates

Z
Y
X
Base coordinates

Work Object Coordinate System

Define coordinate systems

Object
User User

32
Jogging demonstration
Position the robot joints
Major Axis
Minor Axis
Increments where required
Position the tool using Linear relative to:
World / Base coordinates
Tool coordinates
Work object coordinates
Increments where required
Position the tool using Orientation relative to:
Tool / Base and Work object coordinates
Practice Tool Alignment

ABB Robotics MYRO Training Centres

I/O SIGNAL

33
IRC5 – FlexPendant (I/O Output)
From the ABB Main Menu Button – Inputs and Outputs

Shown is the Signal Name, Value, Type and if the Simulate feature is
turned on. DI is Digital Input, & DO is Digital Output.

Input and Output Signal

Viewing signal
Tap ABB
Tap Inputs and Outputs
Tap View.
Select signal type

34
 IRC5 Bus and Unit
Bus: Communication system for transmitting data each other. Local, DeviceNet,
Virtual, Fieldbus
Unit: Output signal card connected to field bus. D652, D651, D352, D378…

IRC5 Signals
I/O Unit status is recognized by the system (Board)
Individual input/output signal characteristics can retrieval and manipulate.
Manual operation is only allowable force for the individual signals.
The output signal operation Off press 0 and On press 1
Input Signal Operation: First, press simulation, it can be operated via the same method.

35
 Most Common I/O
Signal type and relationship of critical signals it can be grouped into a separate group.

Input Instruction
Input processing instructions are to wait until you are satisfied the
specified conditions.
Conditions can be such signal conditions, the time, the logical
operation.
Signal state
Signal Name

WaitDI di05_AutoReady, 1; Processing the digital input signal (0/1) object

Specify delay. In seconds (sec)
WaitTime 0.5;
Logical operation (true / false)

WaitUntil di06_Ready = 1;

WaitUntil di05=1 AND di07=0;

WaitUntil di02=1 OR di03=1...;

36
 Output Instruction
Signal
1
Set do03_Clamp;
Reset do03_Clamp; 0 t

Signal
SetDO \SDelay:=1.5, do04, 1; 1

SetDO do04, low; 1.5s

0 t

Signal
PulseDO \PLength:= 0.2, do12; 1

PulseDO \PLength:= 1.0, do12; 0 t

0.2s 1.0s

I/O Instructions

37
 I/O Timing

p10
p40

p30 p20
DT

DT is a time dependant on processor load.

I/O Timing

p10
P40

P30
P20

38
 ABB Robotics MYRO Training Centres

Programming Data

Defining and Using a Tool

tPen

Tool 0

39
Tool Centre Points

Tool Mounting
Flange

+Y

+X +Z

Relative Directions of wrist coordinate system and tool0.

TCP vs. Tool0

1. TCP
2. Tool0

TCP of
TCP of tool0 (= TCP tPen_00
0)

TCP of
tPen_90

Page 80

40
Tool Centre Point Definition Methods
Default Orientation (same direction as tool0)
TCP & Z Just Z direction defined (X stays in same plane as tool0)
TCP & Z, X both Z and X defined
From 3 to 9 approach points

Simple TCP

No rotational difference from the wrist coordinate system

Z
X

41
TCP & Z

Z direction defined

Example of TCP with Z&X directions defined

The TCP’s X&Z directions are rotated differently to the wrist

42
TCP Definition – Default Orient

1
1
4
3
2 4

3 2
Plan view

TCP Definition – Z & X

Tool orientations are defined by the direction the tool is

positioned away from the datum point.
5
Z Elongator point
Jog robot so the tool’s intended Z and X
directions, visually align to the base
coordinate’s Z and X axis.

4 Jog along Base coordinate Z Axis to define

1 tools Z direction
6 3
2
Jog along Base coordinate X Axis to define
tools X direction

X Elongator point

43
Define a Tool

tGripper

Tool 0
TCP
tGripper

Tool Centre Point Definition Method

Menu
Program data
Select tooldata
Show data
New…
Name tool
Initial value or OK and then select tool in list and Edit Value
Mass:= type in kg and Centre of Gravity
Press OK
Press Edit
Select Define
Select Method and number of Points
Select Point 1, jog robot to calibration position and press Modify Position
Repeat for remaining points
Press OK
You will need to activate your TCP in the jog window

44
 Defining a Tool
Create a Tooldata on FlexPendant
Tap ABB : Program Data : Tooldata : Show Data : New

Give tool a name.

Tap Initial Value.
Page down to Mass and enter the weight of the tool in Kg.
Cursor down to COG X and enter a value in mm.
Tap OK : OK : OK

Define a Tool Center point, 4-point Method

Tap the new tool name then press Edit.
Tap Define.
Choose Point 1.
Jog robot to reference pointer.
Tap Modify Position.
Reposition robot.
Tap Modify Position.
Repeat for all four Points.
Tap OK.

45
Define a Tool, 4-point Method

tPen

Fixed point

46
47
48
49
Defining a Tool Load

Every IRC5 has a service routine called LoadIdentify. It is

used to define the mass and center of gravity of a tool
and/or a part that the tool picks up (Payload or Loaddata).

_________________ is used to define external axis loads.

50
Defining a Tool Load
To go to the LoadIdentify routine tap Debug : Call Service
Rout. Select LoadIdentify then tap “Go to”. Then hold the
enable device and start the program.

Then follow the directions as they appear on the screen.

Things to Remember

Before using Load Identification (Load ID) make sure the following
conditions are met:

Remember:
Create Tooldata before
Tool Load.

Create LoadData before

Payload.

51
Responses and Results
When asked to run in slow speed respond NO because nothing is
calculated at slow speed. However, if unsure about tool cable length then
slow speed can be used.
Follow all instructions as requested.
When asked about the angle that axis 6 is to move while performing the
test it is best to select +90 or -90 degrees. This will give the best results.
If the tooling is unable to make this amount of rotation choose other. A
minimum of 30 degrees must be specified.
At the end of the procedure the following information is given
Mass (kg)=
Centrer of Gravity(mm) X=
Centrer of Gravity(mm) Y=
Centrer of Gravity(mm) Z=
Measurement Accuracy = (Should be greater than 80%)
(If not then run again)

Work Object Coordinate Systems

All program positions are attached to a workobject coordinate system

Wobj0 is the default coordinate system and connected to the robot World

Its advisable to use custom work objects as wobj0 can not be moved

pSafe

TCP

wobjBox

World / wobj0

52
Work Objects
Work Object data contains both User and Object Frames

User Object

World

Work Object Frames

p10
(200, 0, 450)
(400, 0, 50)

World User
(300, 60, 0)
Object

53
Work Objects and External Axis

Positioners base frame is defined relative to the world coordinate system

Work object is connected to, and moved by the positioner

Object frame locates the tooling fixture relative to the user frame / faceplate

User frame

Object frame

Calibrating Work Object frames

Both User and Object frames can be defined with calibration points

An active TCP is jogged to each point during the calibration

Y1
Y1

X1 X1
X2

X2

World

54
Work Object Definition Methods

User and Object Coordinate Systems are usually both defined

at the same position.

Jogging along axis Work Objects

55
Work Objects Summary

WObjData allows robot targets to be stored relative to a work piece coordinate

system.

Many work object data’s may be defined, but only one can be active at a time.

Programs can be reused quickly following changes in the robot installation e.g. if a
fixture is moved, just redefine user coordinate system.

Accuracy is maintained when loading programs created in RobotStudio.

Robot can be jogged along the axes of the work objects, object frame.

Work Object Definition Method (page 76 in pocket guide)

In the jogging window activate the TCP that you will use to define Workobject
Menu
Program data
Select wobjdata and tap Show Data
Select New…
Name work object
Press OK
Press Edit
Select Define
Select ‘3 points’ for user frame and ‘No Change’ for Object frame definition
Jog the tool to the User X1 point select and Modify Position
Repeat for User X2 and User Y1
Press OK and view the calculated result
Press OK to close
You will need to activate your workobject in the Jogging window in order to program or jog
relative to it.

56
 Exercise

1. Create a tool center point for the Gripper attached on the robot using the 4
point metho
2. Write the accuracy values of your tool creation:
• Min Error ________________
• Mean Error _______________
• Max Error ________________

3. Define the load for the tool.

4. Activate the new tool and test using the “Reorient” motion.
5. Setup a Programmable Key to close and open the gripper.
6. If time permits make another tool with the Pen in the gripper.
7. Save the program to the Flash Drive.

ABB Robotics MYRO Training Centres

Load and Run Program

57
Loading a program
To create a new program or load an existing program or Save a program:
Tap ABB
Tap Program Editor
Select Robot Task
Tap Tasks and Programs
Select a Task if multiple robots
Tap File
Tap Load Program
To load an existing program

Before Programming

The following four tasks should be completed before

creating a new program.
1. _______________________________________
2. _______________________________________
3. _______________________________________
4. _______________________________________

58
 Creating a new Program
Old program will be removed
The new program is temporarily named ‘NewProgramName’
A ‘main’ routine is created within a ‘MainModule’

Create a program
To Create a new program:
(If no program exists)
Tap ABB
Tap Program Editor
Select Robot Task
Tap New.
Give your program a name
Tap OK

59
 Creating a new program in IRC5

A new program file is created (.pgf)

A MainModule with main routine is created

Creating Routines
How to create and program routines.
Must be in the Program Editor.
Tap Routines : File
New Routine : Tap “ABC…” to
change the name.
Tap OK.
Select the routine.
Tap Show routine.

60
Introduction to Joint & Linear Motion

P1 Joint Move

Linear Move

P2

MoveJ or MoveL? - Which one to use?

MoveJ

Joint interpolation is often the fastest way to move between two points as the robot
axes follow the closest path between the start point and the destination point (from
the perspective of the axis angles). Use when in open spaces such as moving
from one fixture to another.

MoveL

LINEAR interpolation is the most accurate motion between two points. The robot
will maintain a straight line of the TCP from the starting point to the end point. If this
is not possible an event will be generated. Use when robot is moving close to
other objects such as fixtures or parts.

61
Positional Movements Instructions (Common Picklist)

Speed Data Tool Data

MoveJ *, v1000, z50, tool0;

Robot Position
Zone data

Move Instructions

MoveJ pHome, v500, z5, tGripper

MoveL pHome, v500, z5, tGripper

In the instruction above:

pHome
The robot is moving to _________________
v500
At a speed of ________________________
z5
With a zone of _______________________
tGripper
And a TCP of ________________________

62
Zone
Zone data describes how close to the destination position
the axes must be before the next instruction can be executed.

Robot path during non stepwise motion Programmed

position

p2
p1

Zone size
MoveL p1, v100, z10, tool0;
MoveL p2, v100, z10, tool0;
MoveL p3, v100, z10, tool0;

p3

Circular Movement

MoveC

pCircle20

pCircle30

pCircle40

63
 Circular Movement

Circle with MoveC’s

pCircle20

This robtarget can be copied and pasted

pCircle3
pCircle50 0

pCircle40
Press Modify pos

Inserting Move Instructions

To add instructions to your program:
Tap Add Instruction
Jog robot into position
Tap MoveJ or MoveL
Jog robot to next position
Repeat

64
Sample Simple Program

o position in air
x position on paper
ROBOT

o pHome

o p60
p40 x x p10

x p50

p30 x x p20

Changing a Program

Select item to
change by double
Tapping.

Then choose new

value and press
OK.

65
Modifying a Position

Step to the move

to be modified.

Jog the robot to

the new position.

Tap
Modify Position

Debug

Program
Pointer (PP)

66
Function Offset

Function Offset
In the Move command position definition, choosing
function will enable move with offset (Offs). A
displacement of the robot position.
Example
Used to displace a position
Move type Speed
from original position
C, J, L Accuracy

Move_ Offs(pStart,-100,0,0), v500, fine, toolx;

Z
Position data to Offset
Y
be displaced
X Offset
Offset

Making a Perfect Circle

To Make a Perfect Circle

MoveL pStart, v500, fine, toolx;
MoveC Offs(pStart,-100,-100,0),Offs(pStart,-200,0,0),v500,z1,toolx;
MoveC Offs(pStart,-100,100,0), pStart,v500,z1,toolx;

Which direction will

the circle be drawn?

CW or CCW

67
Offset Example

Example

Square with Offsets

MM X
Example 100
Which quadrant will
the square be drawn?
75
1 2
50
25 1 2 3 4
100 75 50 25 -25 -50 -75 -100
Y MM

-25 pSTART
-50
3 4
-75
-100

From the previous example program:

_____________is the FIRST point of drawing a square and also the
____________ point of the square.

68
 Exercise

1. Add to your new program three routines that draws a circle, a

Square, and a Triangle using only one taught point.

Extra … Create a routine that draws a spiral from 5mm to

100mm in steps of 5mm.

Running Programs in Manual Mode

Procedure

Step Action Info/Illustration

1 Switch the robot to Manual Mode.

DANGER!
Before running the robot, please observe the safety
information in section DANGER – moving
manipulators are potentially lethal!

69
Running Programs in Manual Mode
Procedure

Step Action Info/Illustration

3 Press Enable Device.

4 Press the Start button on the FlexPendant.

Run / Start Program

Execute Backward/Forward
Stop program

Starting Execution
Procedure

Step Action Info/Illustration

1 To run a selected execution use the “Run" button on

the FlexPendant's hardware button key set.

Run / Start Program

Execute Backward/Forward
Stop program

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Stepping Instruction by Instruction
In Manual Mode, the program may be executed step-by-step forwards or
backwards
There are number of dedicated hardware buttons on the FlexPendant

Programmable button 1. How to define it's function is in the

IRC5 Pocket Guide.

Programmable button 2. How to define it's function is in the

IRC5 Pocket Guide.

Programmable button 3. How to define it's function is in the

IRC5 Pocket Guide.

Programmable button 4. How to define it's function is in the

IRC5 Pocket Guide.

RUN button. Starts program execution.

STEP BACKWARDS button. Steps the program one

instruction backwards.
STEP FORWARDS button. Steps the program one
instruction forwards.
STOP button. Stops the program execution.

Stepping Instruction by Instruction (2)

Select stepping mode
Step Action Info/Illustration
1 Selection of step mode.

Stepping forward
Step Action Info/Illustration
1 Press the FWD button on the FlexPendant as
shown in the illustration on earlier page.

Stepping backward
Step Action Info/Illustration
1 Press the BWD button on the FlexPendant as
shown in the illustration on earlier page.

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Stopping Execution
Procedure

Step Action Info/Illustration

1 During operation with hold-to-run control:

Release the hold-to-run button.

2 During operation without hold-to-run control:

Press the STOP button on the FlexPendant unit.

3 When running in step-by-step mode, the robot will Execute next instruction by
stop after executing each instruction. pressing FWD or BWD again.

Saving a Program
To create a new program or load an existing program or Save a program:
Tap ABB
Tap Program Editor
Select Robot Task
Tap Tasks and Programs
Select a Task if multiple
robots
Tap File
Tap Save Program as:
To save a program

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 Saving program in IRC5
A folder with the same name as the program is created
This folder contains the MainModule, Sub modules and the program file
The program file (.pgf),is an extensible mark-up language, ‘XML’, file that lists all
program modules in the task
System Modules are NOT saved

Folder created with

same name

Saving Individual Modules

Individual, Program or System modules can be saved
Select in ‘Program Editor’ and ‘Save Module As…’ from File menu

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Loading Modules

Loading Program and System modules from the Program Editor

Exercise

1. Go to your assigned robots and create a simple program as described in

this section. Then test your program. Each student should make their
own program. (Do not use I/O until all participants have created and tested
their programs.)

2. What happens when you press the E-Stop button while the robot is
running? Can you restart the robot from where it stopped?

3. Save the program to the Flash Drive.

4. Practice pressing buttons on the FlexPendant. If you have any questions

ask the instructor.

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 ABB Robotics MYRO Training Centres

STRUCTURED
PROGRAMMING

Jackson Structured Programming (JSP)

JSP method:
Structure
Well defined routines
- easy to test Proc Call
- easy to re-use Instruction
- easy to trace faults
Easy to read
Main routine
(proc main)

MAIN

rPickUp rSquare rDropOff

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 Sample Program
MAIN r_Lathe;
MoveJ pOvrLathe, v1000, z10, tGripper;
MoveJ pHome, v1000, fine,
MoveL pin_Lathe, v400, fine, tGripper;
tGripper;
Reset do9_Grip;
WaitDI di1_Style1, 1;
MoveL pOvrLathe, v800, fine, tGripper;
r_Feeder1 PulseDO\Plength; = 1, do7_Start_Lathe;
r_Lathe; Wait DI di7_Lathe_Done, 1;
MoveL pin_Lathe, v400, fine, tGripper;
r-Conveyor
Set do9_Grip;
RETURN;
MoveJ pOvrLathe, v1000, z10, tGripper;
r_Feeder1; RETURN;
MoveJ pOvrPart, v500, z30, tGripper; r_Conveyor

MoveL pOnPart, v500, fine, tGripper; MoveJ pOvr_Conveyor, v1000, z60, tGripper;

Set do9_Grip; MoveL pOn_Conveyor, v800, fine, tGripper;

© ABB Inc.134

MoveL pOvrPart, v500, z30, tGripper; Reset do9_Grip;

RETURN; MoveL pOvr_Conveyor, v1000, z60, tGripper;

RETURN;

IRC5 Task Structure

Robot Task

Program File.pgf

MainModule.mod

Program Data

Main System Modules.sys

Routines
Routine Program Data

Routines

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IRC5 Task Structure
Robot Task

Program File.pgf

Program Modules.mod

Program Data
System Modules.sys
Main Program Data
Routines Program Data
Routine
Routines
Routines

What are Modules

A module is a group of routines and data.
The module that contains the main routine is the MainModule
System modules are always present in memory and can be used to save
your default data
Filename extensions are

XXXXX.mod Module
XXXXX.sys System Module
XXXXX.cfg Parameter File
XXXXX.pgf Program File

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Routines

Repetitive instruction sequences, that occur frequently in the program,

should form their own routines.

Routines separate the program into smaller more easily understood

parts, these can then be called anywhere in the program using the
ProcCall instruction.

A Max of 16 characters are allowed for naming routines, meaningful

names such as PickBlock, CutSquare and Put_Part etc will make the
program easier to follow and operate.

Routines can be tested by moving the Program Pointer to a routine.

ABB Robotics MYRO Training Centres

BACKUP AND RESTORE

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Topics
Backup
Why?
When?
How?
Precautions
What is stored

Backup
Having a valid backup is necessary for fast recovery:
If the system behaves differently. (Other than normal)
After software upgrades or reinstallation.

Tap ABB
Tap Backup and Restore
Tap Backup Current System

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Backup
What does a backup contain?
All of the files/folders stored under Home directory in your system on your
flash drive.
The system parameters (e.g naming of I/O signals)
All current programs, modules, and tasks currently in memory.
A backup contains the info that allows your system to go back to behave as it
did when the backup was taken.

Backup
Always
Give your backup a good name. Push ABC to go to the key board to type the name of the backup.
Pay attention to the Backup Path, this is the location where the backup will be stored. Push the … to
change the location.
You should create a Backup folder to store the file in.

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Backup and Restore – Backup the System

Backup and Restore – Backup the System

Use the green arrow up folder to go up a level till you get to the “hdoa” or “USB” or “bd0”. Then select
desired location.

To create a
new folder

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Backup and Restore – Backup the System

ABB recommends performing a backup:

Before installing new RobotWare
Before making any major changes to instructions and/or parameters to
facilitate the previous setting
After making any changes to instructions and/or parameters and testing
the new settings to retain the new settings

Backup
Procedure

Step Action

1 Tap ABB.

2 Tap Backup and Restore.

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Backup
Procedure

Step Action

3 Tap Backup Current System.

Backup
Procedure
Step Action

4 Is the displayed directory the correct one?

If YES: Tap Backup at the bottom of the screen to perform
the backup to the selected directory.
If NO: Tap … to the right of the directory and proceed below.

A backup file named according to the current date is created.

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Restore
Remember
Proper naming will help to ensure that you are restoring
the correct Backup Folder.

Backup and Restore – Restore the System

ABB recommends performing a restore:

If, for any reason you suspect the program is corrupt
If any changes made to the instructions’ and/or parameters’ settings did
not prove successful, and the previous settings is desired

During the restore, all system parameters are replaced and

all modules from the backup directory are loaded

The Home directory is copied back to the new systems

HOME directory during the warm start

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Restore
Procedure

Step Action

1 Tap ABB.

2 Tap Backup and Restore.

xx0300000439

Restore
Procedure

Step Action

3 Tap Restore System.

The set backup directory is displayed.

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Restore
Procedure
Step Action

4 Is the displayed directory the correct one?

If YES: Tap Restore at the bottom of the screen to perform
the backup to the selected directory.
If NO: Tap … to the right of the directory and proceed below.

Restore
Procedure
Step Action

5 Select the desired directory.

6 When the desired directory is shown, select the correct

backup file and tap OK. Then tap Restore.

The Restore is performed, and the system is warm

started automatically.

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 Exercise

1. Go to your assigned robots and create a Backup of the existing system.

2. Save the Backup to a Backups directory on the Flash Drive and if available
to a memory stick.

ABB Robotics MYRO Training Centres

EVENT MESSAGES

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 Introduction

Event Messages are divided into.

Information
Example: Hold to run must be pressed.
Information is stored in the log.

Warning
Example : Manual movement full speed is selected.
The operator is informed about a potential risk.

Error
Example : Motor On when Emergency Stop is active.
The system cannot operate before a measure is
carried out.

Information

Example: Information at program start:

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 Warning
Example: When the computer detects a situation that can cause a
problem or is a safety risk

Error Message

Example: When the computer detects a problem or possible problem, it

generates an error message with description and action.
Unacknowledged message is displayed in red on the status bar

Unacknowledged
message displayed

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Event Message Content
An Event Message consists of
Description
Consequences (optional)
Probable causes (optional)
Action (optional)

Tap arrow to scroll down

in message!

Reading Event Logs on the FlexPendant

Via ABB - Main menu

Tap status bar – Short cut
Tap on Status Bar to see
Event log.

Or Tap ABB then Event

Log to see Event log.

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Event Log
Symbol Code Title
Time stamp

Event Log

Scroll the list with the yellow arrows

Tap on a specific message to get more information

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Event Log
Logs are stored under different topics
Tap view and select the topic of interest
Topic common consist of a mixture of the last created logs

Log Messages
Common 150
All others 20

Event Categories
Category Error number Area__________________

Operational 10xxx Operational Status

System 20xxx Panel unit
Hardware 30xxx Board Failure
Program 40xxx Programming
Motion 50xxx Movement problem
Operation 60xxx Flex Pendant Handling
I/O communication 70xxx I/O board communication errors

ArcWeld 11xxxx Process

SpotWeld 12xxxx Process
Paint 13xxxx Process

Refer to the error number when support is

needed!

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Logs - Events in RobotStudio

The logs or events are avalible in RobotStudio

Refered to as Event Log

Exercise

1. Load the Practice Exercise 4 and practice modifying positions

so that the robot can pick up and set down parts.

2. If time permits simulate recovering the program from the lathe

process. Simulate a problem has occurred and you have to
reset the robot and start production again.

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 ABB Robotics MYRO Training Centres

RESTARTS

Restart
In ABB/Main menu select restart

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Restart Advanced Menu
If another restart than Warm Start is required
Tap Advanced

Summary of Restart Alternatives

W-start (Warm start) Normal restart

When: New hardware, SYSFAIL or change in configuration
Result: Current system is restarted. Program pointer are restored

I-start (Installation start)

When: Add RobWare for a new process
All saved, Restart with default parameters.
Modules & program not loaded

P-start (Program restart)

When: E.g. Changing data in parallel tasks
All data saved on image file for loading purpose
RAPID programs not reloaded

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Summary of Restart Alternatives

X-start (Extra Restart)

When: Change to an existing system: E.g: Glue to Arcweld
All data are saved on an image file, for loading purpose only

C-Start (Cold start) Removes all user inputs and the robot software
When: E.g: A new BaseWare for a system shall be loaded
All data is erased. A boot is necessary if no other system exists in the controller

Special Restart Alternatives

Note! These alternatives are intended for special use only!

Shutdown
When: The UPS system is not working
To start: Turn Power Off & On to restart the system
An image file is carried out as a normal Power Off

B-Start
When: E.g. Recommend action from an error message
Returns the system to the state after the most recent shutdown by either Power
Off or Shutdown
In this case no saving is carried out as for Warm Start

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 ABB Robotics MYRO Training Centres

CALIBRATION /REVOLUTION
COUNTER UPDATED

Calibration – IRC5
Fine Calibrate or Rev.Count update?
Rev.Count update can easily be made with no special
tools.
Fine calibration needs special tools.

97
Rev. Counters
Rev.Counter
Tells how many turns the motor has rotated in the
gearbox.
If value is lost the robot cannot run any programs.
A message notifies that the Rev.Counters need to be
updated.
(e.g. If battery in SMB is drained)

If Event message The

system informs about
difference:
Update so that the robot
and the controller have
the same calibration
values

Updating Rev. Counters

1. Use the Joy stick

and Move the Robot
to the Calibration
Position and align
the witness marks.

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Synchronization Marks
IRB120

A: Axis1, B: Axis2, C: Axis3, D: Axis4, E: Axis5, F: Axis6

Synchronization Marks
IRB2400, 4400

99
Synchronization Marks
IRB2600, 4600

A: Axis1, B: Axis2, C: Axis3, D: Axis4, E: Axis5, F: Axis6

Synchronization Marks
IRB6640

A: Axis1, B: Axis2, C: Axis3, D: Axis4, E: Axis5, F: Axis6

100
Synchronization Marks
IRB6660

A: Axis1, C: Axis2, D: Axis3

E: Axis4, F: Axis5, G: Axis6
A

Synchronization Marks
IRB6700

101
Synchronization Marks
IRB660,760

A: Axis1, C: Axis2, D: Axis3, E: Axis6

Synchronization Marks
IRB360

A: Axis4, B: Axis1-3

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Updating Rev. Counter Procedure
1. Jog the robot to the witness marks / Calibration position.
2. Tap ABB : Calibration
3. Select the robot to be calibrated.
4. Tap Update Revolution Counter
5. Tap YES to confirm this is what you want to do.
6. If needed select the axes to be updated.
7. Tap Update and Update again.

Checking Robot Calibration

MoveAbsJ
Create a new routine (GotoCalib)
Insert MoveAbsJ instruction
Choose star position, Debug / View Value, put all 6 axis
to zero

103
Fine Calibration
Fine Calibration
Tells the current angle of motor shaft when robot is in
sync position
Is tuned in by ABB or on site with special equipment
Only needs to be retuned if a motor / gearbox is replaced

Requires special tools!

Cannot be made correctly
by eye Measurement.

Edit Motor Calibration Offsets

Type in the fine calibration values manually

Use moc.cfg values from Backup, Silver label in back of
manipulator with 6 values, or original Motor Calibration
values on floppy shipped with system.

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 For Emergency Service, Spare Parts, Tech
Support, Questions, Comments, Complaints….
+603 5628 4888

105