ABB Inc.

2016 Robotic Training Catalog (US)

www.abb.us/roboticstraining
 2016 Robotic Training Catalog (US)
Table of Contents
ABB TRAINING PROGRAMS ......................................................................................................... 2
TRAINING FACILITIES ................................................................................................................... 4
RESERVATION INFORMATION ........................................................................................................ 5
TRAINING SCHEDULE ................................................................................................................... 5
ABB Customer Certification Program................................................................................................6

LEARNING PATHS .......................................................................................................................8

Learning Path for Arc Welding..................................................................................................................................9
Learning Path for LaserCutting .................................................................................................................................10
Learning Path for Material Handling .......................................................................................................................11
Learning Path for Paint .............................................................................................................................................12
Learning Path for Spot Welding ..............................................................................................................................13

COURSE DESCRIPTIONS – ROBOT OPERATIONS ............................................................................... 14

COURSE DESCRIPTIONS - PROGRAMMING..................................................................................... 16
COURSE DESCRIPTIONS - ELECTRICAL TROUBLESHOOTING ................................................................. 26
COURSE DESCRIPTION – COMBINED ELECTRICAL & MECHANICAL MAINTENANCE ................................. 29
COURSE DESCRIPTION – BODY IN WHITE ....................................................................................... 30
COURSE DESCRIPTIONS – ROBOTIC WASHER.................................................................................. 31
COURSE DESCRIPTIONS - MECHANICAL MAINTENANCE ................................................................... 34
COURSE DESCRIPTIONS – ADVANCED APPLICATIONS ...................................................................... 37
COURSE DESCRIPTIONS - ROBOTSTUDIO ....................................................................................... 43
COURSE DESCRIPTIONS – CERTIFICATION COURSES......................................................................... 48
TRAINING POLICIES .................................................................................................................. 52
SMART EDUCATION PROGRAM FOR SCHOOLS, COLLEGES, & UNIVERSITIES......................................... 53

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 2016 Robotic Training Catalog (US)
Training Programs

ABB Training Programs

ABB training programs ensure your staff is confident working with flexible automation and enable you to get the
most out of your automation investment.

ABB’s training programs help:

 Improve quality and performance to maximize the return on your system investment
 Increase system up time (MTBF)
 Reduce Mean Time to Repair (MTTR)
 Save operating time, expenses and materials
 Improve employee safety, skills, confidence and morale
We offer:
 Continuing Education Units (CEUs) for all ABB Classes

ABB is IACET Accredited

The International Association for Continuing Education and Training (IACET) has awarded accreditation
status to ABB. IACET Accredited Providers are the only organizations approved to offer IACET
Continuing Education Units (CEUs).
What are CEUs?
Continuing Education Units (CEUs) are nationally recognized by a wide range of organizations,
including professional associations, regulatory boards, corporations and universities.
CEUs can be transferable college credits.

Benefits
Continuing Education Units offer many benefits. The CEUs collected from one type of career training
may be applied to a different profession. Once the CEUs are earned, they are never lost and never
have to be renewed.
Continuing Education Units allow adult professionals to experience a range of training from highly
respected instructors. Employers also see the value of CEUs and know that applicants have gained
knowledge and experience from quality institutions.

How to obtain Continuing Education Units

Continuing Education Units are awarded to individuals who successfully complete each day of an ABB
robotics training course.

 Over 50 courses in programming, electrical troubleshooting, mechanical, software, processes

(such as welding, paint, vision, material handling, spot welding, laser cutting), and customized
courses on a variety of ABB robots
 Certificate programs
 SMART Education programs for educational institutions
 CRAW Certification - American Welding Society (AWS) Certification Program for Robotic Arc
Welding
 Hands-on training in all courses
 Limited sized classes to facilitate an effective and enhanced learning atmosphere

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 2016 Robotic Training Catalog (US)
Training Options
We offer
Open Enrollment Classes/Standard Courses Customized Training
ABB training is scheduled throughout the year at Standard product training can be customized to
either the ABB facility in Auburn Hills, MI or at the target specific applications. Specific product
facility of one of our education affiliates. functions can be targeted in training
Our open enrollment classes consist of ABB presentations to better serve system
standard courses. The courseware is designed in applications.
a logical flow and incorporates hands-on In addition, training can be targeted to an entire
exercises to reinforce the concepts being ABB robot based system. ABB can help you
taught. develop and deliver complete training
Standard classroom training is taught in our open packages from developed courseware on ABB
enrollment classes, as dedicated classes at ABB, systems to facility development which suits your
or at the customer facility. Standard classroom needs.
training is delivered by an ABB instructor. Rental Robots
The cost for standard classroom training is a set Robotic training equipment can be leased or
fee, based on the course being taught by rented from ABB if desired to fully accommodate
certified ABB instructors. extensive hands-on lab exercises and
Training at Customer Facilities/On-Site demonstrations.
ABB can conduct training courses at a customer ABB’s training robot cells are designed to be
facility. ABB can send one of our instructors with easy to move and easy to set-up.
all of the necessary equipment, tools and The robot requires a minimum of 40 psi of clean
documentation to a customer facility. regulate air. A standard ¼” NPT female quick
At ABB, we take pride in providing the very best disconnect air line attaches to the back of the
in employee development through our carefully robot (air line not supplied).
developed training classes. In plant training is Toolbox Training
either based on our standard courses, or
Toolbox training is:
designed courses specifically for your needs.
 For people who have had formal training,
We tailor our courses to suit specific customer
but require a refresher on a few, specific
requirements.
topics.
ABB offers:
 Informal, hands-on training where the
 Special courses that can be provided, content is flexible and tailored to meet our
usually using standard or adapted modules customer’s needs.
from our existing classes to ensure that our
 Delivered in an "on-the-job" fashion, does not
strict, proven and learning process is
include training manuals/materials.
maintained.
 Conducted at the customer’s facility, using
 Pre and post testing of all students to ensure
their equipment.
that the objectives have been met, and that
students have genuinely learned the subject Note: Either a full-time instructor or a qualified
matter. field service engineer will deliver toolbox training.
 Reports (if requested) about the student’s
progress, and assuming that they have met
the course requirements, a certificate of
completion.
 Formal training at your facility with a mix of
both classroom and line-side instruction.

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 2016 Robotic Training Catalog (US)
Training Facilities

Training Facilities
ABB Robotic classes are conducted in the following locations. To find recommended hotels, directions, attire, etc. go to
http://www.abb.us/roboticstraining and click on the appropriate location.
Auburn Hills, MI
ABB Inc.
1250 Brown Road
Auburn Hills, MI 48326
Note: Parking for the Training Center is in the front of the building. Enter through the
main entrance with the "ABB" over it. Doors open at 7:00am.

Houston, TX
ABB Houston
7210 Empire Central Dr.
Houston, TX 77040
Note: Parking for the Training Center is in the front of the building. Enter through the
main entrance with the "ABB" over it. Doors open at 8:00am.

Appleton, WI
Fox Valley Technical College
1825 Bluemound Drive
Room F131
Appleton, WI 54912-2277
Note: Parking for the Training Center is on the southwest corner of the college. Enter
through door 6 and turn right at the second hallway. The classroom is located in F131A.
The lab opens at 7:30 am.

Birmingham, AL
Jefferson State Community College
Manufacturing Center
2601 Carson Road
Birmingham, AL 35215
Note: The Jefferson State Manufacturing Center is located at the corner of Jefferson
State Parkway and Sunhill Road. Parking for the Training Center is on the Sunhill Road
side. Enter through the main entrance. Manufacturing Center is open from 8:00am –
6:00pm

Tanner, AL
Robotics Technology Park
6505 US Highway 31
Tanner, AL 35671
Note: The Park’s main entrance is located across from Calhoun Community
College.

Vincennes, IN
Vincennes University
Indiana Center for Applied Technology (ICAT)
301 W St Clair Street
Vincennes, IN 47591
Note: Parking is located directly behind the ICAT Building (no parking permit
required). ICAT Building is open from 7:30am – 6:00pm.
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 2016 Robotic Training Catalog (US)
Reservations

Reservation Information

Helpful information to have when registering for a Payment

course: ABB accepts:
1. The controller model you require for training.  Purchase orders
2. The Robot Model.  Credit cards
3. The application you are using the robot for, e.g.,  Checks
material handling, arc welding, paint, LaserCutting,
 ABB training certificates
spot welding.
4. How many students will be attending and on which
dates. All tuition and fees paid by the applicant shall be
refunded if;
5. Where would you like to attend the training? At
ABB’s site or at your location? 1) ABB determines the applicant is not
eligible to take the class before
6. If you would like training on-site, do you have enrollment, or
dedicated robots for training?
2) Cancellation is requested in writing
To make a reservation please pick from one of the within ten (10) business days of
following options: enrollment (an administration fee of
1. Call our 24-Hour Customer Support Center at not more than $25.00 may be retained
by ABB).
1-800-HELP-365, option 1, and then select option 4.
All refunds shall be returned within 30 days.
3. Email your enrollment information to
ABB reserves the right to revise tuition fees and
[email protected].
discontinue a course without notice.
4. Enroll on-line at www.abb.us/roboticstraining.
All prices include:
 Student course materials
 Refreshments
 Lunch at ABB training centers
Training Schedule
Rescheduling/Cancellations
A real-time schedule can be viewed by clicking here. Please notify us two weeks before the start date
if you must cancel or reschedule your training.
Just click on a class to view a copy of the course description,
Purchase orders and/or payments already
start and end dates, location and seats available. You can also
received will be credited toward future classes.
register on-line.
We will bill in full for cancellations received less
than 10 business days before the class start day,
If you are unable to access this real-time schedule link above,
or for non-attendance.
please visit our website at www.abb.us/roboticstraining and
Courses are enrollment dependent and
click on the "Training Schedule" link.
therefore are subject to rescheduling. Should this
occur, we will notify you 10 business days before
we reschedule a class and we will prioritize your
request for attendance in another class. Since
circumstances may require us to reschedule
classes please consider this when arranging
travel. We are not responsible for non-
refundable or penalty airline tickets.
Courses are scheduled Monday through Friday
(unless otherwise specified). Alternate timing is
available upon request.

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 ABB Robotics Customer Certification Program
Training (US)

Gain comprehensive
qualification as an ABB
Customer Certified robot
professional in a specific area
of robotics by completing
ABB’s Customer Certification
program.

Job Functions:
Benefits:
• ABB Customer Certified Maintenance Technician
• Become ABB Customer Certified in your job function
• ABB Customer Certified Robot Programmer
upon successful completion of the program
• Obtain materials and knowledge from ABB expert
Applications:
instructors
• ARC Welding
• Utilize automation technology through our customized
• Laser Cutting
training courses
• Material Handling
• Obtain hands-on training
• Paint
• Spot Welding Process:
1. Register for an ABB course listed in the ABB Customer
Audiences: Certfication learning path (see page 2 of this document)
• Engineers 2. 100% Attendance for each class taken
3. Complete and pass practical and written assessments for
• Service technicians
each class
• Robot programmers 4. Apply for and complete online cumulative exam
• Maintenance technicians 5. Receive ABB Customer Certification within job function
6. Renew certification every 3 years by taking the online
cumulative exam

Note: ABB Customer Certification indicates only that the student has completed applicable course(s) and passed applicable
exam(s), but in no way creates any warranties or further obligations on the part of ABB.

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 ABB Robotics Customer Certification Program (US)
Arc Welding
Job Function Programming Electrical Mechanical Final Exam
Mechanical
Maintenance Technician Programming I for Arc Welding Electrical Service Online Cumulative Exam
Maintenance
Robot Programmer Programming I for Arc Welding Online Cumulative Exam

Programming II for Arc Welding

Programming II

Robot Studio with ArcWare

PowerPac
Paint
Job Function Programming Electrical Mechanical IPS Final Exam
Online
Mechanical
Maintenance Technician Programming I for Paint Electrical Service IPS Cumulative
Maintenance
Exam
Online
Robot Programmer Programming I for Paint IPS Cumulative
Exam
Material Handling
Job Function Programming Electrical Mechanical Final Exam
Programming I for Mechanical
Maintenance Technician Electrical Service Online Cumulative Exam
Material Handling Maintenance
Programming I for
Robot Programmer Online Cumulative Exam
Material Handling
Programming II
for Material Handling
Programming III
for Material Handling
RobotStudio
LaserCutting
Job Function Programming Electrical Mechanical Final Exam
Mechanical
Maintenance Technician Programming I Electrical Service Online Cumulative Exam
Maintenance
Robot Programmer Programming I for LaserCutting Online Cumulative Exam

Programming II for LaserCutting

RobotStudio with Cutware
PowerPac

Spot Welding
Job Function Programming Electrical Mechanical Final Exam
Mechanical
Maintenance Technician Programming I for Spot Welding Electrical Service Online Cumulative Exam
Maintenance
Robot Programmer Programming I for Spot Welding Online Cumulative Exam

Servo Tuning for Spot Welding

Programming II

RobotStudio

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 2016 Robotic Training Catalog (US)
Learning Paths

Learning Paths

Overview
ABB’s Learning Paths are an ideal sequence of learning activities that drives employees to reach proficiency in their
job in the shortest possible time. Learning Paths enable employers and employees to find new ways to drive out time,
waste and variability in training which leads to improved results and reduced costs. Learning Paths have been proven
to reduce time to proficiency by 30-50%.
ABB has created Learning Paths for applications and specific job functions.

Material
ArcWelding Paint Spot Welding LaserCutting
- Operator Handling

- Mechanical Maintenance
- Electrical Maintenance
- Maintenance Engineer
- Robot Programmer

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 2016 Robotic Training Catalog (US)
Learning Paths

Learning Path for Arc Welding

Courses
- Robot Operations for Arc Welding (US419)
- Programming I for Arc Welding (US490)
- Programming II for Arc Welding (US495)
- Electrical Troubleshooting
 IRC5 Controller (US421)
 S4C+ Controller (US357)
- Mechanical Maintenance Courses for Arc Welding
 IRB 1600 Mechanical Maintenance (US415)
 IRB 2400 / IRB 4400 Mechanical Maintenance (US377)
 IRB 2600 / 4600 Mechanical Maintenance (US374)
- Advanced Applications Courses for Arc Welding
 RobotStudio 5 with ArcWare PowerPac (US405)
- Certification Courses for Arc Welding
 CRAW (Certification for Robotic Arc Welding), an AWS certification (US333)
 Electronic Position Switch (EPS) Certification (US489)
 SafeMove Certification (US430)

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 2016 Robotic Training Catalog (US)
Learning Paths

Learning Path for LaserCutting

Courses
- Robot Operations for LaserCutting (US419)
- Programming I for LaserCutting (US496)
- Electrical Troubleshooting for LaserCutting
 IRC5 Controller (US421)
- Mechanical Maintenance Courses for LaserCutting
 IRB 2400 / IRB 4400 Mechanical Maintenance (US377)
- Advanced Applications Courses for LaserCutting
 RobotStudio 5 with CutWare PowerPac (US404)
- Certification Courses for LaserCutting
 SafeMove Certification (US430)

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 2016 Robotic Training Catalog (US)
Learning Paths

Learning Path for Material Handling

Courses
- Robot Operations for Material Handling - Mechanical Maintenance Courses for Material
 IRC5 (US419) Handling
 S4 Operations (US302)  IRC5 Compact Controller & IRB 120
- Programming I for Material Handling Mechanical Maintenance (US370)
 IRC5 (US420)  IRB 140 (US423)
 S4/S4C/S4C+ (US312)  IRB 360 (US424)
- Programming II for Material Handling  IRB 1600 (US415)
 IRC5 (US425)  IRB 2400 / IRB 4400 (US377)
 S4/S4C/S4C+ (US313)  IRB 2600 / IRB 4600 (US374)
- Programming III for Material Handling  IRB 6600 / IRB 6650 / IRB 7600 (US416)
 IRC5/S4/S4C/S4C+ (US427)  IRB 6640 (US432)
- Electrical Troubleshooting for Material Handling  IRB 6700 (US433)
 IRC5 (US421) - Advanced Applications Courses for Material
 IRC5 Compact Controller & IRB 120 Handling
Mechanical Maintenance (US370)  IRC5 Force Control (Machining) (US435)
 IRC5 panel mounted controller for use with  PickMaster 3 (Vision) (US418)
PickMaster (US439)  RobotStudio I (US399)
 S4C+ (US357)  RobotStudio II (US401)
- Certification Courses for Material Handling
 Electronic Position Switch (EPS)
Certification (US489)
 SafeMove Certification (US430)

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 2016 Robotic Training Catalog (US)
Learning Paths

Learning Path for Paint

Courses
- Robot Operations for Paint - Advanced Applications Courses for Paint
- IRC5P (US339)  Cartridge Bell System (CBS) (US346)
 S4P/S4P+ (US306)  Integrated Paint Systems (IPS) (US303)
- Programming I for Paint  Shop Floor Editor (US305)
 IRC5P (US341)  RobotStudio I (US399)
 S4P/S4P+ (US340)  RobotStudio 5 with Paint PowerPac (US402)
- Electrical Troubleshooting for Paint  Shop Floor Editor (US305)
 IRC5P (US344) - Certification Courses for Paint
 S4P+ (US362)  Electronic Position Switch (EPS) Certification
- Mechanical Maintenance for Paint (US489)
 IRB 52 (US390)
 IRB 580 (US387)
 IRB 5400 (US379)
 IRB 5400 (US383)
 IRB 5500 (US385)
 IRB 5500 (US395)

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 2016 Robotic Training Catalog (US)
Learning Paths

Learning Path for Spot Welding

Courses
- RobotOperations Courses for Spot Welding
 IRC5 (US419)
- Programming Courses for Spot Welding
 IRC5 Programming I for Spot Welding (US491)
 IRC5 Servo Gun Tuning for Spot Welding (US492)
- Electrical Troubleshooting for Spot Welding
 IRC5 (US421)
- Mechanical Maintenance Courses for Spot Welding
 IRB 6600 / IRB 6650 / IRB 7600 (US416)
- Advanced Applications Courses for Spot Welding
 RobotStudio I (US399)
- Certification Courses for Spot Welding
 Electronic Position Switch (EPS) Certification (US489)
 SafeMove Certification (US430

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 Introduction & Training Concepts
Course Descriptions – Robot Operations

Course Descriptions – Robot Operations

Robot Operations for Material Handling, Arc Welding, LaserCutting, Spot Welding
IRC5 – 2 days – Course Code: US419
S4/S4C/S4C+ - 2 days – Course Code: US302
The goal of this class, available for all robot types, is to provide students who have little or no prior exposure to
robot technology, knowledge and confidence on how to operate the robots using the teach pendant.
Topics include:
- Safety precautions used while programming and program execution
- Operating controls and indicators on the robot controller
- Instruction identification and program flow
- Positioning the robot by use of joystick control
- Basic program modification techniques
Course objectives: After successfully completing the course, the participant should be able to:
- Practice all areas of safety as they pertain to the robot
- Identify and use the teach 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 teach pendant
- Modify movement instructions in a basic program
- Use input and output instructions in a basic program
- Manually execute portions of a basic program
Student profile: This course is intended for personnel responsible for starting and operating the robot.
- Operators and non-skilled laborers
Prerequisites:
- No formal requirements.

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 Introduction & Training Concepts
Course Descriptions – Robot Operations
Robot Operations for Paint
IRC5P – 2 days – Course Code: US339
S4P/S4P+ - 2 days – Course Code: US306
The course goal is to teach students how to operate and modify the robot programs using the paint teach
pendant.
Topics include:
- Safety precautions used while programming and program execution
- Operating controls and indicators on the robot controller
- Positioning the robot by use of joystick control
- Basic program modification techniques
Course objectives: After successfully completing the course, the participant should be able to:
- Practice all areas of safety as they pertain to the robot
- Identify and use the paint teach 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 paint teach pendant
- Use input and output instructions in a basic program
- Use, describe and edit paint process instructions
Student profile: This course is intended for personnel responsible for starting and operating the robot.
- Operators and non-skilled laborers
Prerequisites:
- No formal requirements

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 2016 Robotic Training Catalog (US)
Course Descriptions - Programming

Course Descriptions - Programming

Programming I for Material Handling
IRC5 – 4½ days – Course Code: US420
S4/S4C/S4C+ - 4½ days – Course Code: US312
The course goal is to teach students how to operate and program the robot using the teach pendant.

Topics include:
• Safety precautions used while programming and program execution
• System Description
• Event messages
• Positioning the robot by use of joystick control
• Program creation procedures
• Program modification techniques
• Backup and Restore
• Tool Center Points
• Work Objects
• Program Flow
• Working with numbers
• Operator Communications
• Circles and Offsets
• Clocks and Hot Editing

Course objectives
After successfully completing the course, the participant should be able to:

• Practice all areas of safety as they pertain to the robot

• Properly startup, operate, and shut down the robot
• Properly identify and recover from robot errors
• Perform program storage and retrieval
• Manual and program control of inputs and outputs
• Create Tool Center Point data
• Edit programmed positions
• Create a program with subroutine structure
• Perform editing techniques
• Program instructions, such as, output control, decision making, operator dialog, and clock
• Name I/O and data with proper names
• Identify system parameters
• Define Work Objects

Student profile This course is intended for personnel responsible for operating the robot, creating programs and
editing programs. Such as:
• Technicians
• Engineers
• Service Personnel
• Supervisory Personnel
• System Integrators

Prerequisites:
No formal requirements

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 2016 Robotic Training Catalog (US)
Course Descriptions - Programming
Programming II for Material Handling
IRC5 – 4½ days – Course Code: US425
S4/S4C/S4C+ - 4½ days – Course Code: US313
The goal of this course is to provide instruction in high level programming features and techniques. Designed for
students who have successfully completed the Programming I for Material Handling class and who need a
greater depth of knowledge. This course does not provide a review of the Programming I for Material Handling
class. This class begins where the Programming I for Material Handling class left off.
Topics Include:
- Building and configuring Robot Software
- Online and offline program editing
- Advanced declarations of modules, routines and data
- Programming with interrupts and Traps
- Searching and program displacements
- Error handling, backward handling, and undo handling
- Advanced motion instruction
- World zones
Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the robot system
- Create, Configure, and Download system software
- Create and Use Modules, Routines, and Data
- Create advanced Tool Center Points
- Program with Search Instructions
- Program with Position Displacement Instructions
- Program using Error Handling
- Program Interrupt Instructions, Traps, and Events
- Use Joint Configuration Instructions
- Setup and program World Zones
- Use Motion Control Instructions
Student profile: This course is intended for people that have attended the Programming I for Material Handling
class course but require greater knowledge of programming features.
- System programmers or technicians with existing / developing programming skills
Prerequisites:
- Programming I for Material Handling class (US312 or US420)

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 2016 Robotic Training Catalog (US)
Course Descriptions - Programming
Programming I for Paint
IRC5P – 4½ days – Course Code: US341
S4P/S4P+ - 4½ days – Course Code: US340
The course goal is to teach students how to operate and program the robot using the paint teach pendant and
RobotStudio software (IRC5P only)
Topics include:
- Safety precautions used while programming and program execution
- Operating controls and indicators on the robot controller
- Positioning the robot by use of joystick control
- Program creation procedures
- Program modification techniques
Course objectives: After successfully completing the course, the participant should be able to:
- Practice all areas of safety as they pertain to the robot
- Identify and use the controls necessary for robot operation
- Run robot system in manual or automatic mode
- Interpret and respond to error codes
- Load, create, save, delete, check and edit basic programs using the paint teach pendant, RobotStudio,
ShopFloor Editor and Robview 5 software
- Verify robot synchronization using the calibration method
- Use movement instructions in a basic program
- Use input and output instructions in a basic program
- Learn proper use of routine instructions
- Add and use PaintWare functionally into a program
- Teach line tracking with a moving conveyor
- Teach object tracking with a moving conveyor
Student profile: This course is intended for students that are required to start and operate the robot, create
programs, and edit programs.
- Engineers
- Service personnel
- System integrators
- Supervisory personnel
Prerequisites:
- No formal requirements
- Understanding of Windows or computer programming is helpful

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Course Descriptions - Programming
Programming I for LaserCutting
IRC5 – 4½ days – Course Code: US496
The goal of the course is to train the student to safely use the FlexPendant to create laser cut routines, set and
change cut data and edit existing programs.
Topics include:
- Overview of laser cell functionality
- Overview of laser process equipment functionality
- Program Creation Procedures Within the Production Manager Environment
- Utilization of the Laser Cut Instructions
- Shape Tuning Methods
Course objectives: After successfully completing the course, the participant should be able to:
- Operate the functionality of the laser cell
- Perform the functionality of the laser process components of the cell
- Operate the functionality and use of Production Manager
- Set up the Laser Cell and equipment
- Create new laser cut programs from the FlexPendant
Student profile:
- Engineers
- Maintenance technicians
Prerequisites:
- Laser processing knowledge is recommended

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Course Descriptions - Programming
Programming I for Spot Welding
IRC5 – 4½ days – Course Code: US491
The goal of the course is to train the student to safely use the FlexPendant to create spot weld routines, set and
change weld data and edit existing routines.
Topics include:
- Safety precautions while programming and operating the robot system
- Operator controls and indicators on the FlexPendant and operators panel
- Overview of spot cell functionality
- Overview of spot process equipment functionality
- Program Creation Procedures
- Utilization of the spot welding instructions
- Equipment setup
- Correct positioning of the robot using the FlexPendant and various motion types
- FlexPendant menus and displays for entry of welding routines, program commands and spot data
Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the Robot and the welding system
- Safely start up the controller and move the Robot using the joystick
- Identify and use all the buttons on the FlexPendant
- Interpret and respond to Event Messages
- Load, create, save, delete, check or edit programs using the Robot FlexPendant
- Verify Robot calibration offsets
- Define a TCP, using the 5 point method
- Use movement and spot welding instructions in a basic welding routine
- Set up the spot weld equipment
- Create and execute routines
- Use work objects for Jogging and movement reference
Student profile:
- Welding cell programmers and engineers
Prerequisites:
- Spot welding experience
- Microsoft PC operating training or experience for Windows 3.1, 95, or NT

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Course Descriptions - Programming
Programming I for Arc Welding
IRC5 – 4½ days – Course Code: US490
The goal of the course is to train the student to safely use the FlexPendant to create weld programs, set and
change weld data, and edit existing programs.
Topics include:
- Safety precautions while programming and operating the robot system
- Operator controls and indicators on the FlexPendant and operators panel
- Correct positioning of the robot using the FlexPendant and various motion types
- Production Manager structure and operation
- ArcWare program commands and functions
- FlexPendant menus and displays for entry of welding routines, program commands and weld data
- Positioning of the part using a positioner
- Setting-up and using the ABB “BullsEye” device to create and check tool center points
Course objectives: After successfully completing the course, the participant should be able to:
- Safely operate robot welding cell
- Create routines using proper structure
- Operate and use the “Production Manager” program to create new welded part programs and modify
existing programs
- Save and load part programs to and from disk
- Perform and save system parameters
- Use the positioner to properly orient the part for welding
- Recognize and recover from basic system errors
Student profile:
- Welding cell programmers and engineers
Prerequisites:
- GMAW training or similar welding experience
- Microsoft PC operating training or experience for Windows 3.1, 95, or NT

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Course Descriptions - Programming
Accelerated Programming for Material Handling (Integrators Only)
IRC5 – 4½ days – Course Code: US426
This course is designed for students with strong programming skills (not necessarily ABB products). A quick paced
combination of our IRC5 Programming I for Material Handling (US420) & IRC5 Programming II for Material Handling
(US425) courses, this course provides a brief overview of IRC5 Programming I for Material Handling (US420), then
instruction in IRC5 Programming II for Material Handling (US425) features and techniques.
Topics include:
- Safety precautions used wile programming and - Identify and manipulate data values
program execution - Apply the theory of singularity at a basic level to
- Operating controls and indicators on the robot anticipate problem areas in programs
controller - Use the search instruction and error handling
- Positioning the robot by use of joystick control instructions
- Program creation procedures - Use program displacement instructions
- Program modification techniques - Use interrupt instructions and trap routines
- Setup programmable keys - Use event handling routines
- Interpret and respond to error codes - Use advanced I/O instructions
- Creating and using Tool Center Points - Use instructions to enhance robot performance
- Creating and using Work Objects - Use the Multitasking
Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the robot system - Use decision making instructions in a basic
- Identify and use the FlexPendant program
- Run the robot system in manual mode and - Use registers and math instructions in a basic
automatic mode program
- Interpret and respond to event messages - Use FlexPendant communication instructions in a
- Load, create, save, delete, check, and edit basic program
basic programs using the FlexPendant and - Use time instructions in a basic program
RobotStudio Online software - Use offsets for movement instructions
- Verify robot synchronization using a calibration - Use work objects for position reference
routine - Dynamically change data values
- Create and Define a tool center point - Use instructions to avoid singularity
- Use movement instructions in a basic program - Perform robot searches, displacements, and
- Use input and output instructions in a basic error handling
program - Program interrupts and Trap routines
- Create routines, and use routine instructions in a - Create and use background tasks
basic program
Student profile: This course is intended for personnel responsible for starting and operating the robot, creating
programs and editing programs.
- Engineers
- Service personnel
- System integrators
- Supervisory personnel
Prerequisites:
- This course is intended for someone who has a strong robot programming background, but is not familiar
with ABB robots.

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Course Descriptions - Programming
Programming II for Arc Welding
IRC5 – 4½ days – Course Code: US495
The goal of this course is to provide instruction in high level programming features and techniques for welding
applications. Designed for students who have successfully completed the IRC5 Programming I for Arc Welding
(US490) class and who need a greater depth of knowledge. This course does not provide a review of the IRC5
Programming I for Arc Welding (US490) class. This class begins where the IRC5 Programming I for Arc Welding
(US490) class left off.
Topics include:
- Safety precautions used while programming and program execution
- Operating controls and indicators on the robot controller
- Positioning the robot by use of joystick control
- Program creation procedures
- Creating and using Work Objects
- Setting up Base Frames
- Setup and configure the robot
- Program displacement instructions
- Use interrupt instructions and trap routines
- Production Manager and GAP
- Use instructions to enhance robot performance
- Weld Guide III
- SmarTac to include 1D searching and touch sensing, and laser searching
Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the robot system
- Identify and use FlexPendant
- Run the robot system in manual mode and automatic mode
- Interpret and respond to event messages
- Set-up and download software
- Create and define tool center point/BullsEye
- Setup Base Frame
- Setup coordinated motion
- Discuss multi-move concepts
- Use error handlers for welding and interrupts and trap routines
- Use welding instructions
- Use work objects for position reference
- Perform robot searches, displacements, using the SmarTac concepts, and the Search 1D with the touch
sensor and laser sensor
- Set-up the Weld Guide III and weld a part
Student profile: This course is intended for personnel responsible for starting and operating the robot, creating
programs and editing programs.
- Engineers
- Service personnel
- System integrators
- Supervisory personnel
Prerequisites:
- Programming I for Arc Welding (US490)

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Course Descriptions - Programming
Servo Gun Tuning for Spot Welding
IRC5 – 4½ days – Course Code: US492
The goal of the course is to train the student to properly setup, commission, and tune servo controlled spot
welding guns.
Topics include:
- Safety precautions while working with Spot Welding guns
- Why Servo tuning is required
- Proper tool center point definition
- Servo Gun Commissioning
- Servo Gun Calibration
- Setup Servo Gun Deflection
- What is Tune Master
- Servo Gun Tuning
- Servo Gun Verification
- Motor Commutation
- Motor Wiring
- Resolver Wiring
- Complete configuration of unknown gun and motor
- Configuring Kv

Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the Robot and the spot welding system
- Setup a Tool Center Point including Arm Load and Tool Load
- Reference Tool Center Point in program for procedures
- Commission a Servo Gun using a starter file
- Calibrate a Servo Gun
- Install and use Tune Master to tune a Servo Gun
- Describe the 7 critical steps of complete tuning
- Identify and fix commutation problems
- Identify and fix motor wiring problems
- Setup an unknown gun and motor for the first time
- Setup KV for an unknown motor

Student profile:

- Welding cell programmers and engineers

- Technicians
- Engineers

Prerequisites:

- Spot welding experience

- US491 Programming I for Spot Welding
- Microsoft PC operating training or experience for Windows XP or 7

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Course Descriptions - Programming
Programming III for Material Handling
IRC5 – 4½ days – Course Code: US427
S4/S4C/S4C+ – 4½ days – Course Code: US427
The goal of this course is to provide instruction in high level programming features and techniques. Designed for
students who have successfully completed the IRC5 Programming II for Material Handling (US425) or S4
Programming II for Material Handling (US313) class, and who need a greater depth of knowledge. This course
does not provide a review of any previous programming class. This class starts where the S4 / IRC5 Programming
II for Material Handling course left off.
Topics include:
- Multitasking programming techniques
- Creating instructions, functions, and data
- Serial communication capabilities
- Load ID and collision detection
- Advanced program displacement
- World zones
- Uploading and downloading of programs
- Using OPC
- User Authorization System
Course objectives: After successfully completing the course, the participant should be able to:
- Create background tasks
- Create custom instruction
- Create custom functions
- Create custom data types
- Transfer information via serial channel
- Setup load ID and collision detection
- Manipulate data values
- Program robot to load and unload programs
- Define zones for monitoring
- Setup and basic use of OPC
- Setup user levels and grants
Student profile: This training is targeted for system programmers or engineers with advanced programming
skills.
Prerequisites:
- Programming II for Material Handling (US425 or US313).

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Course Descriptions – Electrical Troubleshooting

Course Descriptions - Electrical Troubleshooting

Electrical Troubleshooting (non-Paint Robots)
IRC5 – 4½ days – Course Code: US421
S4C+ – 4½ days – Course Code: US357
The course is designed to teach students how to identify the electrical components, theory of operation, and
introduce proper troubleshooting procedures on the robot controller. Approximately 50% of the course is hands-
on troubleshooting of actual robot system and controller.
Topics include:
- Theory of operation of the robot controller
- Safety precautions used while troubleshooting the robot controller electrical system
- Description of components in the robot controller
- Principles of logical troubleshooting from power up through emergency stop loop and servo-system
- Input/output interfacing between the robot controller and peripheral equipment
Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the robot system
- Identify and use the teach pendant
- Run the robot system in manual mode and automatic mode
- Interpret and respond to event messages. Use event logs
- Identify different parts of the robot modules and arm
- Load system software
- Troubleshoot Power ON circuits
- Troubleshoot computer and drive system to a board level
- Troubleshoot Motors ON / Run Chains circuits
- Troubleshoot the Motors, brakes, and resolvers
- Properly calibrate the robot after a motor change
Interface an input device and an output device to the robot
Student profile:
- Industrial electricians
- Electrical Troubleshooting technicians
- Engineers
- Supervisory personnel
Prerequisites:
- Familiarity with use of electronic test equipment (voltmeter and oscilloscope)
- Basic understanding of digital electronics is helpful
- Programming I for Material Handling (US420), Programming I for Arc Welding (US490), Programming I for
LaserCutting (US496), or Programming I for Spot Welding (US491) is strongly recommended.

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Course Descriptions – Electrical Troubleshooting
Electrical Troubleshooting (Paint Robots)
IRC5P – 4½ days – Course Code: US344
S4P+ – 4½ days – Course Code: US362
This course is designed to teach students how to identify the electrical components, theory of operation, and
introduce proper troubleshooting procedures on the robot controller. Approximately 50% of the course is hands-
on troubleshooting of actual robot system and controller.
Topics include:
- Theory of operation of the robot controller
- Safety precautions used while troubleshooting the IRC5P robot controller electrical system
- Description of components in the robot controller
- Principles of logical troubleshooting from power up through emergency stop loop and servo-system
- Input/output interfacing between the IRC5P robot controller and peripheral equipment
Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the robot system
- Identify different parts of the robot controller and manipulator
- Troubleshoot computer and drive system to a board level
- Load system software and system operating parameters
- Interface an input and an output device to the robot controller
- Interpret and respond to event message – use event logs
- Troubleshoot power ON circuits
- Troubleshoot purge circuits
- Troubleshoot Motors ON / run chains circuits
- Troubleshoot the motors, brakes, and resolvers
Student profile:
- Industrial electricians
- Electrical Troubleshooting technicians
- Engineers
- Supervisory personnel
Prerequisites:
- Familiarity with use of electronic test equipment (voltmeter and oscilloscope)
- Basic understanding of digital electronics is helpful
- Programming I for Paint (US340 or US341) is strongly recommended

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Course Descriptions – Electrical Troubleshooting
Electrical Troubleshooting (Panel Mounted Controller)
IRC5 – 4½ days – Course Code: US439
The goal of this course is to teach students how to identify the electrical components, theory of operation, and
introduce proper troubleshooting procedures on the IRC5 Panel Mounted robot controller. Approximately 50% of
the course is hands-on troubleshooting of actual robot system and controller.
Topics include:
- Theory of operation of the IRC5 robot controller
- Safety precautions used while troubleshooting the IRC5 robot controller electrical system
- Description of components in the IRC5 PickMaster robot controller
- Principles of logical troubleshooting from power up through emergency stop loop and servo-system
- Input/output interfacing between the IRC5 robot controller and PickMaster 3 equipment
Course objectives: After successfully completing the course, the participant should be able to:
- Operate the IRC5 control panel and programming unit
- Read and interpret ABB circuit diagrams on the IRC5 robot controller
- Calibrate resolvers and revolution counters
- Analyze and interpret system fault codes
- Troubleshoot and repair basic electrical faults
- Analyze servo-system
- Diagnose and rectify emergency stop conditions
- Make I/O connections to peripheral equipment and safety devices
- Repair and replacement of systems components
- Review “Cold-Boot” procedure
Student profile:
- Industrial electricians
- Electrical service technicians
- Engineers
- Supervisory personnel
Prerequisites:
- Familiarity with use of electronic test equipment (voltmeter and oscilloscope)
- Basic understanding of digital electronics is helpful
- PickMaster 3 (Vision) (US418) is strongly recommended

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Course Description – Combined Electrical & Mechanical

Course Description – Combined Electrical & Mechanical Maintenance

IRB 120 Electrical & Mechanical Maintenance
IRC5 – 4½ days – Course Code: US370
The course is designed to teach students how to identify the electrical components, theory of operation, and
introduce proper troubleshooting procedures on the IRC5 Compact robot controller. In addition, this course will
teach the student how to properly disassemble and reassemble the mechanical unit. It will also teach proper
preventive maintenance procedures.
Topics include:
- Theory of operation of the IRC5 Compact robot controller
- Safety precautions used while troubleshooting the IRC5 Compact robot controller electrical system
- Description of components in the IRC5 Compact robot controller
- Principles of logical troubleshooting from power up through emergency stop loop and servo system
- Input / Output interfacing between the IRC5 Compact robot controller and peripheral equipment
- Proper safety precautions used while performing mechanical repair
- Operation of robot control and mechanical unit
- Description and operation of mechanical components
- How to use manual for repair and ordering of spare parts
Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the robot system
- Identify and use the FlexPendant
- Run the robot system in manual mode and automatic mode
- Interpret and respond to event messages, use event logs
- Identify different parts of the robot modules and arm
- Load system software
- Troubleshoot Power ON circuits
- Troubleshoot computer and drive system to a board level
- Troubleshoot Motors ON/Run Chains circuits
- Troubleshoot the Motors, brakes, and resolvers
- Calibrate the robot
- Interface an input device and an output device to the robot
- Perform safety precautions used while doing mechanical repair
- Properly start-up, operate and shutdown the robot
- Describe the operation of mechanical components
- Disassemble and reassemble mechanical unit
- Use the manual for repair and ordering of spare parts
- Describe preventive maintenance procedures on the robot
- Calibrate robot
Student profile:
- Industrial electricians
- Electrical Troubleshooting technicians
- Engineers
- Supervisory personnel
- Industrial personnel required to mechanically repair the robots and to perform regular preventive
maintenance
Prerequisites:
- Familiarity with use of electronic test equipment (voltmeter and oscilloscope)
- Basic understanding of digital electronics is helpful
- Programming I for Material Handling (US420) is strongly recommended
- Mechanical background or experience is helpful
-

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Course Description – Body in White

Course Description – Body in White

Flexlifter and PLP Operations and Maintenance
IRC5 – 4½ days – Course Code: US479
The course goal is to teach students how to properly operate and perform preventive maintenance
procedures to their equipment.
Topics include:
- Proper safety precautions used while working with the equipment
- Description and operation of mechanical components
- Description and operation of electrical components including the IRC5 Controller
- Setting up and accurately running an existing and a new job / recipe
Course objectives: After successfully completing the course, the participant should be able to:
- Perform safety precautions used while doing periodic maintenance
- Start-up and shut-down the robot correctly
- Describe the operation of mechanical and electrical components
- Make modifications to the program for new positions
- Perform preventive maintenance procedures on the robot
- Perform a backup of the programs on the IRC5 controller side
Student profile:
- Industrial personnel required to mechanically repair the robots and to perform regular preventive
maintenance
- Operations personnel required to operate and modify existing jobs
Prerequisites:
- Mechanical background or experience is helpful
- Industrial and HMI experience is helpful

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Course Descriptions – Robotic Washer

Course Descriptions – Robotic Washer

Robotic Washer Operator Course
IRC5 – 1 day – Course Code: US470
The goal of this course is to provide students with a high level understanding of the operating principles of the
ABB Robotic Washer. This course provides instruction to personnel involved with the operations of the ABB
Robotic Washer.

Course Content
- General introduction / ABB contact information
- Safety: ECPL general instruction, General safety, Personal safety, Mechanical safety, Electrical safety,
Pneumatic safety, Arc flash safety, Safety hazards, Safety devices (description and locations), MSDS (link to
pdf documents)
- Machine Description: Purpose of machine, Sequence of operation, Component description / Machine
Layout
- Operation: HMI Screens, HMI Panel, E stop location, Stack light description, Start up, Auto mode, Manual
mode, Shut down, Dry cycle, Bypass, Run out, Back up, E-stop recovery, General fault recovery, Entry
procedure
- Operator Maintenance: Overview, Maintenance table
Student Profile: This course is intended for personnel responsible for starting and operating the ABB Robotic
Washer.
- Cell Supervisors
- Cell Operators
Prerequisites
- Robot Operations for Material Handling (US419) or Programming I for Material Handling (US420)
- Basic knowledge of automated assembly equipment
- Basic understanding of Windows software operating cells
- Basic computer skills (identification of hardware and terminology)
- Basic engine assembly buildup operation and processes

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Course Descriptions – Robotic Washer
Robotic Washer, Electrical Maintenance
IRC5 – 1 day – Course Code: US471
The course goal is to provide skilled trades personnel and overview of the ABB Robotic Washer, and instruction
on how to troubleshoot and repair the ABB Robotic Washer. The training will also include diagram overview and
system component interfaces. This course provides instruction to personnel involved with the operations of the
ABB Robotic Washer and is structured to provide a combination of classroom lecture and hands-on training. Task
certification sheets will be documented to ensure understanding course content.
Topics:
- Safety precautions used while operating the ABB Robotic Washer
- ABB Robotic Washer component location and description
- Operating procedures (start-up, shut-down, e-stop, etc.)
- Preventive maintenance requirements
- Basic troubleshooting & fault recovery
- Electrical architecture (PLC) and PLC/robot interface of the cells
- Review cell electrical diagrams
- Review HMI screens
- Electrical troubleshooting techniques
- Fault recovery techniques
Course Objectives: After successfully completing the course, the participant should be able to:
- State the purpose, function, location, and operating characteristics of major electrical and controls
components associated with the ABB Robotic Washer
- Demonstrate the ability to identify and locate safety devices on the cell
- Recognize requirements for safe operation and maintenance
- Demonstrate the ability to read and interpret the system electrical schematics
- Identify control devices and process screens in HMI operator panels
- Identify PLC/robot interface used in the cell
- Demonstrate the ability to interpret fault messages and repair the fault
- Identify electrical failures and possible cell failures
Student Profile: This course is intended for personnel responsible for starting, operating and electrically
maintaining the ABB Robotic Washer.
- Skilled Trades Electricians
- Supervisors
Prerequisites
- ABB Robotic Washer, On-Line Operator Course
- Programming I for Material Handling (US420)
- Electrical Troubleshooting (US421)
- Electrical schematic reading
- Basic knowledge of automated assembly equipment
- Basic understanding of Windows operating systems and computer skills (identification of hardware and
terminology)
- Electrical Journeymen Status

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Course Descriptions – Robotic Washer
Robotic Washer, Mechanical Maintenance
IRC5 – 1 day – Course Code: US472
The course goal is to provide skilled trades personnel and overview of the ABB Robotic Washer, and instruction
on how to mechanically maintain the ABB Robotic Washer. This course provides instruction to personnel involved
with the operations of the ABB Robotic Washer and is structured to provide a combination of classroom lecture
and hands-on training. Task certification sheets will be documented to ensure understanding course content.
Topics:
- Proper safety precautions used while performing mechanical repair
- Maintenance and mechanical repair of cell components
- Operating procedures (start-up, shut-down, e-stop, etc.)
- Basic review of PM requirements
- Mechanical fault identification
- Mechanical troubleshooting techniques
- Hydraulic and pneumatic cell adjustments
- Cell component lubrication
Course Objectives: After successfully completing the course, the participant should be able to:
- Demonstrate knowledge of equipment safety features
- Demonstrate knowledge of system operating procedures
- Demonstrate the ability to operate the cell using HMI control screens and manual push button panels
- Locate and identify all major system components
- Demonstrate the ability to perform preventive maintenance tasks
- Demonstrate the ability to maintain the washer mechanical components (media roll, filters, UV light, valves)
- Demonstrate the ability to troubleshoot the system using the HMI fault codes
- Locate each cell component lubrication point and describe lube requirement
- Demonstrate knowledge of cell hydraulic HPU’s and components
- Demonstrate knowledge of pneumatic cell components
- Demonstrate the ability to troubleshoot mechanical, hydraulic and pneumatic problems associated with
the cell components
Student Profile: This course is intended for personnel responsible for starting, operating, maintaining, and
mechanically repairing the ABB Robotic Washer.
- Skilled trades personnel required to mechanically repair and adjust the components
Prerequisites:
- ABB Robotic Washer, On-Line Operator Course
- Basic knowledge of automated assembly equipment
- Basic understanding of Windows operating systems and computer skills (identification of hardware and
terminology)
- Basic engine assembly buildup operation and processes
- Mechanical Journeymen Status
- Mechanical component blueprint reading and understanding capabilities
- Hydraulic and pneumatic schematic reading

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Course Descriptions – Mechanical Maintenance

Course Descriptions - Mechanical Maintenance

Mechanical Maintenance (non-Paint Robots)
IRB 140 – 2 days – Course Code: US423
IRB 360 – 2 days – Course Code: US424
IRB 1600 – 2½ days – Course Code: US415
IRB 1520ID / IRB 1600ID / IRB 2600ID – 2½ days – Course Code: US372
IRB 2400 / IRB 4400 – 2½ days – Course Code: US377
IRB 2600 / IRB 4600 – 3 days – Course Code: US374
IRB 6600 / IRB 6650 / IRB 7600 – 3 days – Course Code: US416
IRB 6640 – 3 days – Course Code: US432
IRB 6700 – 3 days – Course Code: US433
The course goal is to teach students how to properly disassemble and reassemble the mechanical unit. It will also
teach proper preventive maintenance procedures.
Topics include:
- Proper safety precautions used while performing mechanical repair
- Operation of robot control and mechanical unit
- Description and operation of mechanical components
- How to use manual for repair and ordering of spare parts
Course objectives: After successfully completing the course, the participant should be able to:
- Perform safety precautions used while doing mechanical repair
- Properly start-up, operate, and shutdown the robot
- Describe the operation of mechanical components
- Disassemble and reassemble mechanical unit
- Use the manual for repair and ordering of spare parts
- Describe preventive maintenance procedures on the robot
- Calibrate robot
- Perform assembly disassembly of the upper arm according to product manual
Student profile:
- Industrial personnel required to mechanically repair the robots and to perform regular preventive
maintenance
Prerequisites:
- Mechanical background or experience is helpful

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Course Descriptions – Mechanical Maintenance
Mechanical Maintenance (Paint Robots)
IRB 52 – 2½ days – Course Code: US390
IRB 580 – 3 days – Course Code: US387
IRB 5400 – 3 days – Course Code: US379
IRB 5500 – 3 days – Course Code: US385
The course goal is to teach students how to properly disassemble and reassemble the mechanical unit. It will also
teach proper preventive maintenance procedures.
Topics:
- Proper safety precautions used while performing mechanical repair
- Operation of robot control and mechanical unit
- Description and operation of mechanical components
- How to use manual for repair and ordering of spare parts
Course objectives: After successfully completing the course, the participant should be able to:
- Perform safety precautions used while doing mechanical repair
- Properly start-up, operate, and shutdown the robot
- Describe the operation of mechanical components
- Disassemble and reassemble mechanical unit
- Use the manual for repair and ordering of spare parts
- Describe preventive maintenance procedures on the robot
- Calibrate robot
Student profile:
- Industrial personnel required to mechanically repair the robots and to perform regular preventive
maintenance
Prerequisites:
- Mechanical background or experience is helpful

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Course Descriptions – Mechanical Maintenance
Mechanical Maintenance with Process Arm (Paint Robots)
IRB 5400 with Process Arm – 4½ days – Course Code: US383
IRB 5500 with Process Arm – 4½ days – Course Code: US395
The course is designed to teach students the theory of operation, disassemble and reassemble the vertical arm,
horizontal arm, horizontal arm drive unit, drive shafts, spring assembly, and motors. Additionally, how and when
to PM the robot, fluid control, process arm components, and troubleshooting. When applicable, disassemble and
reassemble the gear pumps and valve pack.
Topics include:
- Proper safety precautions used while performing mechanical repair
- Theory of operation of robot controller and mechanical unit
- Description and operation of mechanical components
- Overview of paint process arm components
- How to use manual for repair and ordering of spare parts
Course objectives: After successfully completing the course, the participant should be able to:
- Perform safety precautions used while doing mechanical repair
- Properly start-up, operate, and shut-down the robot
- Describe the operation of mechanical components
- Disassemble and reassemble mechanical unit
- Use the manual for repair and ordering of spare parts
- Identify and describe the paint process components
- Overview the 2x2 valves
- Overview of paint process arm preventive maintenance procedures
- Perform preventive maintenance procedures on the robot
- Calibrate robot with calibration fixtures
Student profile:
- Industrial personnel required to mechanically repair the robots and to perform regular preventive
maintenance
Prerequisites:
- Mechanical background or experience is helpful.
- Ability to navigate through the paint teach pendant

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Course Descriptions – Advanced Applications

Course Descriptions – Advanced Applications

Cartridge Bell System
4½ days – Course Code: US346
The course goal is to teach the students how to use the ABB Cartridge Bell System (CBS).
Topics include:
- Safety precautions used while programming and program execution
- System overview of the controls and indicators on the CBS
- Installation requirements of the CBS equipment
- Preventive maintenance
- Repair procedures
- Calibration of dispensing equipment
Course objectives: After successfully completing the course, the participant should be able to:
- Identify all equipment associated with the CBS application
- Learn operation sequencing and functionality
- Observe wearable items and frequency of maintenance
- Troubleshoot and repair faulty equipment
- Learn calibration procedures
- Disassemble and assemble IFS, Cartridge, and Cartridge Bell
- Identify wearable components
Student profile: This course is intended for students that are required to start and operate the CBS dispensing
equipment
- Engineers
- Service personnel
- Supervisory personnel
- System integrators
Prerequisites:
- S4P Programming for Paint (US340) or IRC5P Programming for Paint (US341) is strongly recommended

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Course Descriptions – Advanced Applications
Integrated Process Solution (IPS)
4½ days – Course Code: US303
The course goal is to teach students how to use and troubleshoot the IPS configuration interface.
Topics include:
- Safety precautions used when making changes on the fluid control parameters
- General overview of Gun Control, Open and Closed Loop signal configuration
- Editing the IPS.cfg and Elo.cfg files
Course objectives: After successfully completing the course, the participant should be able to:
- Practice safety as it pertains to the robot and fluid controls
- Identify hardware and describe the purpose of the Applicator and fluid control system
- Operate and setup software and monitor robot configuration across the CAN bus
- Make changes to the IPS.cfg and Elo.cfg files to establish
- Gun Control, Open and Closed Loop Fluid Control using a text editor
- Download the configuration file to the MCOB
- Monitor operation from a computer using the Terminal software
- Make adjustments to the Applicator Control for delays in the fluid system
Student profile:
- This course is intended for students that are required to finalize and adjust the systems paint process for fluid
applications
- Engineers
- Service Personnel
- System Integrators
Prerequisites:
- Prior knowledge of S4P or IRC5P pendant operation, Robot Programming and System Parameter
Configuration is helpful

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Course Descriptions – Advanced Applications
Robot Framework
IRC5 – 1 day – Course Code: US445
The objective of this course is to show to the student how an ABB IRC5 can be configured within Integrated Frame-
Work for Controls (IFWC) software environment.
Topics include:
- Theory of operation of IFWC
- ABB IRC5 robot integration with IFWC
- ABB IRC5 robot to PLC communication
Course objectives: After successfully completing the course, the participant should be able to describe how
IFWC functions when it comes to:
- ABB IRC5 robot creation and usage
- Setup IFWC in user’s computer
- Create IFWC robot system
- Download IFWC system to ABB IRC5 controller
- Configure a user RAPID module to interface with IFWC
- ABB IRC5 robot to PLC communication and usage
- Simple PLC demonstration in integrating IFWC
- Simple HMI demonstration in using IFWC
Student profile:
- Engineers
- System integrators
Prerequisites:
- Programming I for Material Handling (US420)
- Understanding of Microsoft Windows 7 operation within a PC
- Knowledge of PLC functionality
- Siemens STEP7 (for demonstration purpose)
- WinCC (for HMI controls)

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Course Descriptions – Advanced Applications
Force Control (Machining) (US435)
IRC5 – 4½ days – Course Code: US435
The course goal is to teach students how to operate and program the robot using Force Control.
Topics include:
- Loading computer software
- Setup Force Control graphical user interface
- FC commands
- Force Controlled pressure applications
- Force Controlled speed change applications
Course objectives: After successfully completing the course, the participant should be able to:
- Practice all areas of safety as they pertain to the robot
- Properly start-up, operate, and shut-down the robot
- Load computer software
- Use the graphic user interface
- Create machining routines
- Edit programmed positions
Student profile: This course is intended for personnel responsible for starting and operating the robot, creating
programs and editing programs.
- Engineers
- Service personnel
- Supervisory personnel
- System integrators
Prerequisites:
- Understanding of the machining process is helpful

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Course Descriptions – Advanced Applications
PickMaster 3 (Vision)
IRC5 – 4½ days – Course Code: US418
The goal of this course is to teach students the basic application of PickMaster 3, as well as familiarize them with
its features.
Topics include:
- Presentation and overview of PickMaster 3
- Feature scope of PickMaster 3
- Conveyor set-up
- Vision calibration, modeling and tuning
- Line creation
- PickMaster 3 RAPID program
- Project creation
- Hardware components and writing
- Logging
- Performance and limiting factors
Course objectives: After successfully completing the course, the participant should be able to:
- Describe hardware components
- Describe wiring configurations
- Explain basic performance capabilities
- Explain licensing procedures
- Setup a Line
- Calibrate a conveyor
- Calibrate a camera
- Verify accurate Calibrations
- Train part models
- Configure PickMaster using common variations
- Setup containers
- Modify RAPID code
- Setup Indexed Work Areas
- Create Backups
- Explain Load Balancing
- Explain Adaptive Task Completion (ATC)
- Use PickMaster for Inspections
- Perform diagnostics on system
Student profile:
- This training is targeted to the people that will be applying and integrating PickMaster 3, as well as those
who will use and maintain an installed PickMaster 3-based system.
Prerequisites:
- Programming I for Material Handling (US420)
- Programming II for Material Handling (US425) is strongly recommended
- Advanced PC user

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Course Descriptions – Advanced Applications
Shop Floor Editor
3 days – Course Code: US305
This course is designed to teach students how to maximize Shop Floor Editor Software. The student will learn how
to hot-edit robot programs without interrupting production and how to optimize robot movements and
Applicator trigger positions using the robot program and work piece. The course also covers the technique of
three-dimensional work piece image creation and how to overlay robot programs onto those images.
Topics include:
- Safety precautions while operating and programming with Shop Floor Editor software
- Graphic digitalizing of brush files and color display of programs
- File editing functions such as point modification, speed or velocity adjustments and Applicator trigger
positions adjustments as well as advanced logic functions
- Adjustments of paint parameters
- Creating and converting programs into work pieces or importing CAD drawings for robot program editing
Course objectives: After successfully completing the course, the participant should be able to::
- Demonstrate the ability to practice all areas of safety as they pertain to the robots and using the Shop Floor
Editor software
- Describe the function of the Shop Floor Editor software
- Demonstrate the ability to manipulate programs files, brush files, system files, and IPS files
- Demonstrate the ability to edit and save files
- Edit program data such as position, velocity, acceleration, Applicator triggering, and process parameters
on the robot from the Shop Floor Editor software
Student profile: This course is intended for people that are familiar with Windows
- Engineers
- Service personnel
- System integrators
Prerequisites:
- S4P Programming for Paint (US340) or IRC5P Programming for Paint (US341)
- Microsoft PC operation training or equivalent PC experience

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Course Descriptions – RobotStudio

Course Descriptions - RobotStudio

RobotStudio I
IRC5 – 4½ days – Course Code: US399

The goal of this course is to teach the students how to use the ABB RobotStudio 5 software for use with IRC5 controllers. This
class will cover everything that the general user would need to know.

Topics include:
- Basic controls
- Building a station
- Robot moves
- Robot programs
- Local origin
- Tools
- Task Frames
- Auto Path Feature

Course objectives: After successfully completing the course, the participant should be able to:
- Start and utilize RobotStudio 5 Software
- Create a simulation station
- Create and attach tooling to robot simulation
- Create robot motion
- Create robot programs
- Create basic geometry modeling
- Import external graphic files
- Use the I/O simulator
- Create work objects
- Set local origin Set task frames
- Use Auto Path feature
- Use Signal Analyzer
- Record simulations
- Edit RAPID code using RAPID editor
- Watch data values while simulation executes
- Set-up and use Event Manager
- Create simulation of real robot

Student profile: This course is intended for

- Engineering personnel that are interested in computer simulation software.
- Those responsible for simulating robot layout and reach capabilities and robot program simulation.
- Any one responsible for creating new part programs for existing robots with computer experience.

Prerequisites:
•IRC5 Programming I for Material Handling (US420)
•IRC5 Accelerated Programming for Material Handling (Integrators Only) (US426)
•IRC5 Programming I for Arc Welding (US490)
•IRC5 Programming I for Spot Welding (US491)

- The attendee must have a good, working knowledge of Windows

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Course Descriptions – RobotStudio
Course Descriptions - RobotStudio
RobotStudio II
IRC5 – 4½ days – Course Code: US401

The goal of this course is to teach the students how to use more advanced features of ABB
RobotStudio 5 software for use with IRC5 controllers. This course is an extension of the US399
RobotStudio I course.
Topics include:
- Smart Components
- Multi Move
- Conveyor Tracking
- Screen Maker
- Graphic Tools
- Advanced Modeling
- Mechanisms
- Non-ABB external axis
- System Builder
- Code Snippets
- Rapid Profiler
Course objectives: After successfully completing the course, the participant should be able to:
- Create simulations with interactive
objects such as conveyors, in-feeders,
grippers, and more.
- Create simulations and program multiple
robot applications.
- Setup and program conveyor tracking
- Use graphic tools to change lighting,
textures, and the look of objects.
- Create complex 3 dimensional objects
- Create objects that move in simulations
other than robots.
- Create external axis that are not
standard ABB axes.
- Use System Builder to create virtual
robot systems.
- Advanced RAPID Editing techniques

Student profile: This course is intended for

- Engineers
- Maintenance technicians
- Robot Programmers

Prerequisites:
Must have completed one of the following courses before attending:
o US399 RobotStudio
o US402 RobotStudio with Paint PowerPac
o US404 RobotStudio with Cutware PowerPac
o US405 RobotStudio with ArcWare PowerPac
o US406 RobotStudio with Palletizing PowerPac

- The attendee must have a good, working knowledge of Windows

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Course Descriptions – RobotStudio
RobotStudio 5 with Paint PowerPac
IRC5P – 4½ days – Course Code: US402
The goal of this course is to teach the students how to use the ABB RobotStudio 5 software for use with IRC5P
controllers. This is not RobotStudio Online.
Topics include:
- Basic controls
- Building a station
- Creating robot moves
- Creating basic geometry modeling
- Creating robot programs
- Creating work objects
- Set Up Conveyor Tracking
- Set Up Smart Components
- Using I/O simulator
- Using external axis
- Setup a Paint Simulation Station with Paint Power Pac
Course objectives: After successfully completing the course, the participant should be able to:
- Start and utilize the RobotStudio 5 software
- Create simulation station
- Create and attach tooling to robot simulator
- Create robot motion
- Create robot programs
- Create basic geometry modeling
- Import external graphic files
- Use the I/O simulator
- Create work objects
- Simulate Conveyor Tracking
- Create simulations with paint motions
- Utilize the Paint PowerPac
Student profile: This course is intended for
- Engineering personnel that are interested in computer simulation software.
- Those responsible for simulating robot layout and reach capabilities and robot program simulation.
Prerequisites:
- Programming I for Paint (US341)
- The attendee must have a good, working knowledge of Windows

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Course Descriptions – RobotStudio
RobotStudio 5 with CutWare PowerPac
IRC5 – 4½ days – Course Code: US404
The goal of this course is to teach the students how to use the ABB RobotStudio 5 and CutWare PowerPac
software for use with IRC5 controllers.
Topics include:
- Basic controls
- Building a station
- Robot moves
- Robot programs
- Local origin
- Tools
- Task Frames
- Auto Path Feature
- Simulations
- Event Manager
- Work objects
- I/O simulator
- External axis
- Geometries
- Station Signals
- Off-line to online calibration
- Laser Cutting Off-line Programming with RobotStudio
- Introduction to RobotStudio
- Setup of Customer Part into RobotStudio
- Creation of Laser Cut Programs using the Cutting PowerPac
- Download Procedures to Robot Controller
- Laser Cutting Off-line Program Calibration
- Calibration of Off-line program to coincide with part
- Using Robot Studio for Off-line fine tune adjustments
- Using FlexPendant Applications for On-line fine tune adjustments
- Maintaining program quality throughout lifetime of part
Course objectives: After successfully completing the course, the participant should be able to:
- Laser Cutting Off-line Programming with RobotStudio Cutting PowerPac
- Successfully create laser cutting program offline for their part
- Laser Cutting Off-line Program Calibration
- Successfully download a program into the production cell
- Adjust the program with RobotStudio based on quality feedback
- Tune the program from the FlexPendant based on quality feedback
Student profile: This course is intended for
- Engineers
- Maintenance technicians
- Robot Programmers
Prerequisites:
Programming I for Material Handling (US420) OR IRC5 Programming I for LaserCutting (US496)
- The attendee must have a good, working knowledge of Windows

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Course Descriptions – RobotStudio
RobotStudio 5 with ArcWare PowerPac
IRC5 – 4½ days – Course Code: US405
The goal of this course is to teach the students how to use the ABB RobotStudio 5 and ArcWare PowerPac software
for use with IRC5 controllers.
Topics include:
- Basic controls - Simulations
- Building a station - Event Manager
- Robot moves - Work objects
- Robot programs - I/O simulator
- Local origin - External axis
- Tools - Geometries
- Task Frames - Station Signals
- Auto Path Feature - Off-line to online calibration
- Arc Welding PowerPac Off-line Programming with RobotStudio
- Introduction to RobotStudio
- Setup of Customer Part into RobotStudio
- Creation of welding programs using the ArcWare PowerPac
- Download Procedures to Robot Controller
- Arc Welding PowerPac Off-line Program Calibration
- Calibration of Off-line program to coincide with part
- Using Robot Studio for Off-line fine tune adjustments
- Using FlexPendant Applications for On-line fine tune adjustments
- Maintaining program quality throughout lifetime of part
Course objectives: After successfully completing the course, the participant should be able to:
- Arc Welding PowerPac Off-line Programming with RobotStudio
- Successfully create welding program offline for their part
- Arc Welding PowerPac Off-line Program Calibration
- Successfully download a program into the production cell
- Adjust the program with RobotStudio based on quality feedback
- Tune the program from the FlexPendant based on quality feedback
Student profile: This course is intended for
- Engineers
- Maintenance technicians
- Robot Programmers
Prerequisites:
- Programming I for Material Handling (US420) OR Programming I for Arc Welding (US490)
- The attendee must have a good, working knowledge of Windows

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Course Descriptions – Certification Courses

Course Descriptions – Certification Courses

Certification Program for Robotic Arc Welding (CRAW)
IRC5 – 4 days (prep course); 1 day (exam) – Course Code: US333
ABB, Inc. is an American Welding Society (AWS) Approved Test Center for the certification testing for Robotic Arc
Welding – Operators and Technicians (CRAW). This certification allows many welding personnel employed in
various welding sectors to measure themselves against standards for their occupation. It also signifies that the
CRAW Operator or Technician has demonstrated the capability of working with various codes, standards, and
specifications. Since proof of active practice or re-examination is required every three years, certification also
signifies that the CRAW Operator or Technician is current with the welding industry.
Program responsibilities: AWS
- Sets principal requirements for taking the examination
- Is responsible for defining the content of all exams and how they are conducted
- Scores all written exams in their headquarters facility in Miami, Florida
- Will issue certification credentials
- Will review and process all applications and set and collect all appropriate fees for certification
ABB:
- Offers a Prep Course to prepare the Operator or Technician for the certification exam. Before taking the
CRAW Prep Course/Exam, submit the Robotic Arc Welder Application to the American Welding Society
(AWS) along with appropriate fees. The application can be downloaded from the AWS website. This should
be submitted to the AWS at least six weeks prior to the class/exam date.
- Will provide the personnel, facilities, and procedures to administer the certification testing for AWS including
written exams, and performance testing using a designated arc welding robot.
- Develops procedures to assure equipment operates within required parameters that traceability of test
materials is maintained.
Program levels:
Level 1- Company defined
Level 2- CRAW Operator
Required:
- Minimum two years of welding experience
- Good mechanical aptitude
- One year diploma in welding or robotic instruction
- Good written and oral communication skills
Recommended:
- Programming I for Arc Welding (US490) class is strongly recommended
- Perform all functions on a teach pendant
- Proper operation knowledge of tools and hardware (i.e., Plasma cutting, band saws, etc.)
- Destructive testing methodology background (i.e., Macro Etch, band test, etc.)
- Safety instruction on robot mechanical and control circuitry
- Visual inspection capability of system

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Course Descriptions – Certification Courses
CRAW (US333)(continued)
Level 3- CRAW Technician
Required:
- Must be a current Certified Weld Instructor
- Meet level 1 and 2 requirements
- Minimum five years of welding experience
- Two year associates degree in Welding/Robotics/Electrical or equivalent
Recommended:
- Knowledge of quality measuring tools for measuring weld cross sections
- Familiar with personal computers
Certification Tests: Each level of certification has a required group of tests that must be completed within a
certain time period and with a passing rate of 75%.
Robotic Programming:
- The operator will manipulate a robotic welding cell to achieve desired results performing a number
of tasks to demonstrate familiarity with the components.
Closed Book Exam:
- Over 130 multiple choice questions are included in the closed book test to evaluate the subject’s
general knowledge of weld setup, processes, terminology, symbols, safety, testing, conversions,
programming, and logic.
Performance Tests:
- Consisting of a series of 25 tasks and welding a test plate. The performance test must be taken
within three months of taking the written exam and meeting the requirements of the MacroEtch.
- The performance test must be administered by a CRAW-T level instructor at a facility offering the
appropriate type of robot for the student.

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Course Descriptions – Certification Courses
Electronic Position Switch (EPS) Certification
IRC5 – 2 days – Course Code: US489
The goal of this course is to certify the students on how to install and use ABB EPS hardware and software safely.
Topics include:
- Introduction EPS
- Applications that can make use of EPS
- Hardware
- EPS wiring
- Software installation
- Setting up safety users
- Setting up monitored Axis Range
- EPS Wizard
- Recovery from zone violations
Course objectives: After successfully completing the course, the participant should be able to:
- Explain the purpose for EPS
- Identify EPS hardware components
- Describe what makes EPS safe
- Describe different methods of implementing EPS
- Describe software installation requirements
- Setup a Safety User and Safety User Group
- Setup basic EPS system
- Setup EPS safety zones
- Identify and use all EPS wizard screen
- Install EPS hardware
- Load EPS software using RobotStudio Online
- Recover from EPS faults
Student profile:
- This course is intended for those that have to be certified to install and create safety zones using EPS
Prerequisites:
- Programming I for Material Handling (US420)
- The attendee must have a good, working knowledge of Windows

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Course Descriptions – Certification Courses
SafeMove Certification
IRC5 – 3 days – Course Code: US430
This course was designed to teach students how to ensure and configure a high safety level in the robot system
using the advanced features of the SafeMove option. Each student who successfully completes and
demonstrates the requirements for certification with a passing rate of 75% or better, will receive a certificate to
that effect. The certification exam is administered by a Certified ABB SafeMove Instructor.
Topics include:
- System architecture
- Levels of supervision
- Hardware installation
- Software installation
- Software configuration
- Proper configuration
- Testing the safety interlocks
- Verifying limit switch override
- Verifying sync switch operation
- Verifying override operation
Course objectives: After successfully completing the course, the participant should be able to:
- Observe the placement of the hardware
- Review the block diagram
- Review the capabilities and limitations
- Describe active supervision
- Describe passive supervision
- Describe wiring procedures for a relay
- Describe wiring procedures for a safety I/O block
- Describe wiring procedures for the panel unit inputs
- Install safety controller PCB
- Install SMB and command harnesses
- Install power harness
- Install wiring of the sync switch
- Verify a category 0 stop opens the safety relays
- Verify the contact for the limit switch override is plugged or not strapped
- Use SafeMove wizard
- Create a safety group and user
- Create a password for the safety user
- Describe the need for a drive module key
- Activate a configuration
- Verify the operation of a safety output
- Confirm the proper operation of the configuration
Student profile: This course is intended for
- Engineers
- Service personnel
- Supervisory personnel
Prerequisites:
- Robot Operations for Material Handling (US419) or Programming I for Material Handling (US420) is
recommended
- RobotStudio Online and robot operation is helpful
- Understanding of Windows or computer programming is helpful

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Training Policies

Training Policies
Governing Bodies: Owner & Operator of School - ABB Inc.
Prerequisites: ABB requires attendance in prerequisite courses prior to attending our advanced courses. ABB offers a
placement test to test out of a prerequisite course for students who feel they do not need to attend the prerequisite
course due to their years of experience with ABB robots. Please call to inquire about this service.
Registration: Student registration is based on a first come basis. Enrollment may be accepted up to the start of the
class. All students must be 18 years of age or older.
Training Material: All documentation is issued during the class. Any work material issued and used in classes may not
be reproduced either in whole or in part. All software used in classes is the property of ABB and may not be copied
or reproduced. If this stipulation is infringed, we reserve the right to exclude the person concerned from the class and
to take further legal action.
Certificate of Completion: Certificates of completion are awarded to students who attend class daily for the full
duration of the stated course and have demonstrated competence.
Previous Credit & Placement Services & Enrollment: ABB does not provide placement services, nor are they necessary
for enrollment in ABB courses. Courses at ABB are self-contained and therefore credit for previous education cannot
be applied to training conducted at ABB or by ABB instructors at your facility. Enrollment is not restricted to specific
dates or time periods. Classes at ABB are conducted throughout the year and enrollment can be facilitated at any
time.
Conduct: While on ABB premises, no student may use, possess, dispense, distribute, sell or be under the influence of
alcohol, illegal or non-prescribed drugs. The legal use of prescribed drugs or over-the-counter medication is permitted
on the job only if it does not impair student’s ability to perform the job effectively and safely.
Filming: ABB does not permit students to film, record, videotape or photograph any training session.
Dress Code Policy: Attire not permitted in the training lab are shorts, skirts, sandals (open toed shoes), tank tops, and
any inappropriate logos.

Code of Conduct
ABB expects all of its students’ to be treated with respect, their rights upheld and their privacy maintained.

ABB is committed to equal opportunity in the conduct of all of its business activities. ABB will has a zero tolerance policy
harassment of any kind, nor any discrimination forbidden by law including that involving race, religion, national origin,
color, disability, veteran status, marital status, age, sex, pregnancy, height, weight or any other protected status.

Any student, who believes he or she has been subjected to discrimination or harassment, must report that fact
immediately to the training director.

Reports will be investigated and remedial action will be undertaken as appropriate.

Re-admission:
Students dismissed due to conduct, must obtain training director’s approval for re-admission.

Records and Transcripts:

All records are kept for at least seven years.

Training records may be obtained by sending a letter or e-mail to our address, which includes the
following information: student name, address, company, course name and course dates. A $10
processing fee must accompany request. Make checks payable to ABB Robotics America.

Confidentiality:
Students training records, including course materials, test scores, attendance records and evaluations, may be
shared to ensure compliance with, by way of example, curriculum or continuing education requests, grant and
tuition programs or other related requirements.
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SMART Education Program

SMART Education Program for Schools, Colleges, & Universities

Exclusive to ABB is the SMART (Software, Maintenance, and Robotics Training) program, which is offered to qualifying
Educational Institutions.
Education Program Options:
1. ABB SMART Trainer – Receive a Certificate of Completion and purchase ABB training curriculum
2. ABB Certified SMART Trainer – Attend a train the trainer session and be certified to teach
3. ABB Certified Affiliate Trainer - Teach ABB curriculum to students and industry professionals at your training
facility
Benefit:
The SMART program can be utilized by schools to integrate robot training into their existing courses including
Science, Technology, Engineering, and Math (STEM) initiatives.
Education Program Details:
ABB’s robotic packages for education offers schools, colleges and universities instant access to the latest in
automation software and robotics technologies, including:
- ABB’s IRB 120 robot on self-contained mobile cart
- IRC5 compact controller
- 100 licenses for RobotStudio
- Exclusive training and certification of instructors from educational institutions to train students on
programming ABB robots
- Curriculum for programming and offline programming
- Additional options available

Recommended Courses
- US420 IRC5 Programming I
- US425 IRC5 Programming II
- US399 RobotStudio I
- US370 IRB120 Electrical and Mechanical Maintenance

Instructors will:
- Receive instant access to the latest in automation software and robotic technologies
- Obtain the skills to effectively teach students about robot applications after completing the SMART
program
- Learn robotics from the ground up through the completion of our customized training course and hands-on
training
- Receive a certificate of completion upon successful completion of the course
- Save time developing a training curriculum with the option to purchase ABB course materials
Students will:
- Learn about robotic cell hazards, health and safety, and maintenance requirements
- Utilize the same robots and software as in the industry, including the offline programming software
RobotStudio
- Receive hands-on training
- Learn the latest automation technology while applying STEM

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SMART Education Program

RobotStudio 5.15
RobotStudio provides the tools to increase the profitability of your robot system by letting you perform tasks
such as training, programming, and optimization without disturbing production.
Top 10 benefits of using RobotStudio
1. Risk Reduction: Robot reach, path, and cycle time is assured.
2. Quicker Start-up: Logic and motion are already developed.
3. Shorter Change-over: New parts easy to add by importing the CAD data.
4. Increase Productivity: Reduces weeks of potential programming down to days.
5. New usability features added each year.
6. Integrated RAPID Editor: Chromacoding & syntax checking intellisense for less debugging.
7. Available in 64 bit edition.
8. Intuitive Design: Provides a comfortable programming environment.
9. Signal Analyzer: Allows easy viewing of timing and handshaking, and easy debugging including joint limits,
power consumption, and more.
10. Robot Position Monitor: Allows viewing of actual robot position on screen for more intuitive program design

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1-800-435-7365, Option #1, Option #4
www.abb.us/roboticstraining