ABB Robotics

Basic Operating Manual

IRC5P

3HNA018949-001 en Rev.00
Basic Operating Manual
IRC5P

3HNA018949-001 en Rev.00

First Edition: 05 October 2011

Basic Operation, IRC5P

The information in this manual is subject to change without notice and should not be construed
as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this
manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be construed
as any kind of guarantee or warranty by ABB for losses, damages to persons or property,
fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from use of this
manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB’s written
permission.
Additional copies of this manual may be obtained from ABB.
The original language for this manual is English. Any other languages that are supplied have
been translated from English.

© Copyright 2011 ABB All rights reserved.

ABB AS, Robotics
Discrete Automation and Motion
N-4340 BRYNE, Norway
Basic Operating Manual, IRC5P Table of Contents

Table of Contents

Basic Operating Manual, IRC5P

1 Basic Robot Controls 9
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Control Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.1 Operating Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.2 LED Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.1 Control Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.2 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4 Jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.5 Emergency Stop Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 Basic Operation 25
2.1 Starting the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2 Running a Production Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.1 The Production Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.2 The Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Job Queue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.2 The Job Queue Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.4 Stopping the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3 Emergency Situation 33

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Table of Contents Basic Operating Manual, IRC5P

6 3HNA018949-001 en Rev.00 Basic Operation, IRC5P

Basic Operating Manual, IRC5P
This manual provides information on basic operation of the manipulator. It is
assumed that all configurations, preconditions and one-time operations have been
taken care of.

The manual is intended for an operator who controls a standard production program.

For information on programming and other more complicated operations, see the
‘Operator’s Manual, IRC5P’.

WARNING! Before performing any work described in this manual, the Safety
Manual must be read and understood. Work must only be performed by skilled
personnel with the proper training.

The Safety Manual is included in the Software and Documentation DVD following
each robot, and is also shipped with the robot as paper copy, included in the control
cabinet.

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8 3HNA018949-001 en Rev.00 Basic Operation, IRC5P
 1 Basic Robot Controls
1.1 Introduction

1 Basic Robot Controls

1.1 Introduction

Overview The robot consists of following parts:

Control cabinet

Pendant suspension LED Indicator Panel

Operating Panel

Manipulator

Pendant

Manipulator The manipulator carries a tool and is controlled by a number of axes.

Control Cabinet The control cabinet contains the control electronics to drive the manipulator. The
front contains an operating panel and a LED indicator panel.

Pendant The pendant, Paint Teach Pendant Unit PTPU, enables the operator to control the
manipulator. The pendant may be placed on the pendant suspension on the front of
the control cabinet.

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1 Basic Robot Controls
1.2 Control Cabinet

1.2 Control Cabinet

1.2.1 Operating Panel

Panel Overview The operating panel on the front of the control cabinet contains following switches
and indicators:
Mains Power Switch

Switch for applying mains power to the robot system.

Emergency Stop Button

Push/pull button for instant stop of the robot regardless of operating mode.

To reactivate emergency stop chain, the button must be released (pulled out
or rotated clockwise), then the Motor On button must be used.

Purging OK Indicator

Indicator lamp informing the user when the purge sequence is completed at
start-up and the robot is ready for operation.

Motor On/Off Buttons

Used to enable (I) or disable (0) electrical power for the manipulator axis
motors.

The indicator in the On button will be lit when power is applied. (Motor On is
one of many conditions for applying power).

Steady light: Ready for program execution.

Fast flashing light: (4Hz): The robot is not calibrated or revolution counters are
not updated. The motors have been switched On. By fast flashing, call for
service assistance.

Slow flashing light: (1Hz): One of the spray booth safety switches is active.
The motors have been switched Off.

The Motor On button is also used to reset the emergency stop chain and to
enable run chain in Manual mode.

High Voltage On/Off Key Switch

Toggle key switch used to switch power for high voltage equipment On (“I”),
and button used to switch power for high voltage equipment Off (0).

Toggle key switch means that the switch returns to Off position when
released, as indicated by the (“I”) notation.

The switch is only applicable if the robot is fitted with HV controller.

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 1 Basic Robot Controls
1.2 Control Cabinet

Operating Mode Selector

Key switch used to lock the robot in one of the following 3 operating modes:

Automatic / mode: Used for running ready-made programs in

production. Joystick can not be used.

Manual Reduced Speed / mode: Manual mode for programming and

setup. Max. speed: 250 mm/s (600 inches/min.)

Manual High Speed / mode: Manual mode for testing at full program
speed.

WARNING:
The Mode Selector is a key type switch, intended to increase personal safety.
When operating within the working area of the robot, the switch shall always
be in Manual mode, and the operator shall keep the key with him so it is not
possible for other persons to take over control of the robot.

IMPORTANT:
In Manual High Speed mode, the System Speed is by default set to a low
value. This is a safety feature to avoid a ‘high speed surprise’ in case the key
switch was set one notch too far when switching to programming mode. The
system speed must be set to 100% manually in order to obtain full speed.

Mode Change Acknowledge

When leaving Manual Reduced Speed mode, an Acknowledge input is
required. If operated from the pendant, a dialog for this purpose is shown. For
systems controlled by a PLC or RobView, there is a Paint Command available
for this purpose.

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1 Basic Robot Controls
1.2 Control Cabinet

1.2.2 LED Indicator Panel

Description The following gives an overview of the LED indicator panel, and a short description
of the system messages given on the panel. Full description of the messages is found
in ‘Product Manual, Control Cabinet IRC5P’, Trouble Shooting.

CH1 CH2
Emy Stop Panel Enable Main

Emy Stop Pendant Enable Axis

Emy Stop External Enable PIB

Emy Stop Chain Enable SIB

RUN CHAIN

Mode Stop Enable MIB

Enabling Device Enable Manipulator 1

General Mode Stop Enable Manipulator 2

Delayed Stop 2 Ch. Monitoring

SYSTEM
Chain Closed Power status

Robot 1 Temp. Cabinet

DRIVE

Process - 2.1 / 2.2 Enable Chain Closed

Paint Enable Overpressure

HV Chain Pressurized
PROCESS

Encoder 1 - A / B Min. Flow

Encoder 2 - A / B Purge Timer

Start - 1 / 2 Process Status

PIB CAN1 - MS / NS System Status

COMM.

PIB CAN2 - MS / NS Cooling Fan

SPI - Int. / Ext

USER
USER

Display Valid

Panel Section LED Indicator Description

RUN CHAIN - Emy Stop Panel Green - OK.
Status of emy stop (Chain 1-2) Off - Emergency stop button on control cabinet is depressed.
chain and run chain
Emy Stop Pendant Green - OK.
(Chain 1-2) Blinking Green - Hot plug activated.
Blinking Green/Red - Hot plug time out, Emergency stop chain closed.
Blinking Red - Hot plug time out, Emergency stop chain is broken.
Off - Emergency stop button on the pendant is depressed.
Emy Stop External Green - OK.
(Chain 1-2) Off - External emergency stop button(s) is depressed.
Emy Stop Chain Green - Chain closed.
(Chain 1-2) Off - when panel, pendant, emergency stop category 0 and category 1 is open.
Blinking Red - Emergency stop reset fail.
Mode Stop Green - OK.
(Chain 1-2) Off - Auto mode stop is activated.

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 1 Basic Robot Controls
1.2 Control Cabinet

Panel Section LED Indicator Description

RUN CHAIN - Enabling Device Green - Enabling device is depressed.
Status of emy stop (Chain 1-2) Off - Enabling device is released.
chain and run chain
General Mode Stop Green - OK.
(Chain 1-2) Off - General mode stop is activated.
Delayed Stop Green - OK.
(Chain 1-2) Off - Delayed stop is activated.
Chain Closed Green - OK.
(Chain 1-2) Ch1 Blinking Red - Servo disconnect system 1.
Ch2 Blinking Red - Servo disconnect system 2.
Off - Run chain is broken.
DRIVE - Robot 1 Green - Power relay for robot motor drive system is activated.
Status of motor Ch1 Red - Relay KM1 error.
drive system for Ch2 Red - Relay KM2 error.
manipulator and Off - Relay not activated.
paint pumps
Process - 2.1 / 2.2 Green - Chain closed - Relay for process equipment 2.1 (e.g. pump) or motor
drive system 2.2 (e.g. CBS motion) is activated.
Blinking green: Hardware chain closed - Waiting for RID.
Blinking Red: Aux. chain open (Process 2.1) / System 2 interlock open
(Process 2.2).
2.1 Red - Relay KM101 error.
2.2 Red - Relay KM102 error.
Off - Chain open.
PROCESS - Paint Enable Green - Chain closed.
Status of functions (Chain 1-2) Blinking Green: Process interlock open - cabin interlock closed.
related to spray Blinking Red - Divergency in process interlock chain.
booth and paint Off - Cabin interlock chain is broken.
process
HV Chain Green - Chain closed.
(Chain 1-2) Off - Chain open.
Blinking Red: HV Interlock broken.
Encoder 1 - A / B Green - Flashes to indicate phase 1 and 2 from Encoder 1, normally conveyor
(Phase 1-2) encoder.
By encoder frequency below 10Hz, the LEDs will blink: off-off, on-off, off-on,
on-on. A stopped encoder shows one of these combinations.
By frequencies above 10Hz, both LEDs will appear to be constantly lit.
Encoder 2 - A / B Green - As Encoder 1. Encoder 2 may be used as backup for encoder 1 etc.
(Phase 1-2)
Start 1 / 2 Green - Lit when digital input is active. Normally Start 1 input is used as Sync
Switch for conveyor tracking and Start 2 is not used.
COMM. - PIB CAN1 - MS / NS Green - OK.
Status of CAN and Any other status, see ‘Unit Description, IRC5P’, Distributed I/O.
SPI communication
PIB CAN2 - MS / NS Green - OK.
Any other status, see ‘Unit Description, IRC5P’, Distributed I/O.
SPI - Int. / Ext Green: OK.
Red: During SPI initialization.
SPI bus communication between PIB and SIB, MIB (SPI - Int) and between PIB
and external I/O units (SPI - Ext).
SYSTEM - Enable Main Green, blinking each 8th second - Main Computer OK.
Status of the Off - No communication.
different control Blinking Red - Failure.
systems, power
Enable Axis Green, blinking each 8th second - OK. Enable signal from axis computer active.
supply, purge
Blinking Red - Failure, signal not active.
system,
temperature, etc.

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1.2 Control Cabinet

Panel Section LED Indicator Description

SYSTEM - Enable PIB Green - Enable signal from PIB OK.
Status of the Blinking Green/Red - Software not active and Enable Chain - HW OK.
different control Blinking Red during start up - Waiting for loading of FPGA.
systems, power Off - Enable signal lost.
supply, purge Blinking Red - Failure.
system,
Enable SIB Green - Enable signal from PIB OK. Communication between SIB and PIB OK.
temperature, etc.
Off - Communication lost.
Blinking Red - Failure.
Enable MIB Green - Communication between MIB and SIB is OK (MIB OK).
Off - Communication lost.
Blinking Red - Failure
Enable Manipulator 1 Green - OK. MCOB is operative.
Blinking Red - Failure, MCOB not ready.
Indicator lights red during purging sequence.
Enable Manipulator 2 As Enable Manipulator 1, but for 2nd manipulator, such as CBS.
2 Ch. Monitoring Green - OK.
Blinking Red - Failure, divergency in switches and/or relays in safety chain.
Power Status Green - OK.
Blinking Green - Low voltage on measuring system battery.
Blinking Red - One or more supply voltages faulty, e.g. Emergency stop chain
supply.
Temp Cabinet Green - OK.
Blinking Red - Temperature in control cabinet or transformer too high.
Enable Chain Closed Green - OK. Enable chain is active.
Blinking Red - Chain is not active.
Overpressure Green - OK. Purging pressure below maximum pressure limit.
Blinking Red - Pressure is above maximum limit.
Note: If 2 purge systems are used, LED applies for both systems.
Pressurized Green - OK. Purging pressure is above minimum limit.
Blinking Red - Pressure is below minimum limit.
Note: If 2 purge systems are used, LED applies for both systems.
Min. Flow Green - OK. Flow is OK.
Blinking Green - No flow.
Red - Mismatch between purge valve and high flow.
Note: If 2 purge systems are used, LED applies for both systems.
Off - No high flow.
Purge Timer Blinking Green - Purge sequence in progress.
Off - Purge sequence not started or sequence completed.
Process Status Green - 2 channel supervision of process chain OK.
Blinking Red: Chain broken.
Off - Supervision not OK.
System Status Green - System OK.
Blinking Red - System fault.
Cooling Fan Green - OK.
Blinking Red - Cooling fans not running or running with low speed.
Miscellaneous - USER 4 + 3 user definable LEDs.
Status of the LED
Display Valid Green - OK. System indicator board, ALED is active.
board and user
Off - ALED board not active.
defined LEDs
Note that LED is blinking red/green during initialization until communication with
PIB is started.

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 1 Basic Robot Controls
1.3 Pendant

1.3 Pendant

Overview The pendant includes a display and control keys for operating the robot. In addition,
the pendant includes an Emergency Stop button, 2 joysticks and an enabling device.
Joysticks
Emergency
Stop button

Control keys

Enabling device/
Live handle Display
(rear side)

1.3.1 Control Keys

Overview The control keys are grouped with colors according to type of operation.

Navigation Color display Jog menu

Enter

Back

Run Step
control control

Info-key Soft-keys Shift-key

Green - Navigation The two big green keypads are used for menu navigation. The green color indicates
that there are no dangerous operations associated with this group.

The Main menu includes a number of icons showing the available sub-menus. To
highlight an icon, use the navigation arrow keys.

Menu-key
Enter-key

Navigation
arrow keys Back-key

– To select a sub-menu, press the Enter-key

– To return to the previous level, press the Back-key
– To go directly back to the Main menu, press the Menu-key

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1 Basic Robot Controls
1.3 Pendant

Orange - Run Below the navigation keypads are the orange-colored Run-group keys. Using these
keys can result in robot motion directly. The Run keys are Halt, Run, Step forwards
and Step backwards. Also the Jog menu-key that is embedded in the right navigation
pad is orange, to indicate that it has to do with robot motion. See ’Jogging’ on page
20 for description of the Jog menu-key.

Blue - Information • The Info-key is intended to display context-sensitive information about the
current operation.
In most cases, the Info-key serves the same purpose as the Shift-key, so that both
hands can be used (particularly when using Shift-Enter).
• The Shift-key will, as in any ordinary keyboard, enable an alternative action for
some of the keys on the keypad. In some cases, it serves as a shortcut key for
selected operations.
When traversing a list, the functionalities of the navigation arrows and the
Shift-key are like this:
Arrow Direction: Normal Arrow Function: Shift + Arrow Function:
Up Arrow One Line Up Top of list
Down Arrow One Line Down End of list
Left Arrow One Page Up Previous first letter (b -->a)
Right Arrow One Page Down Next first letter (a-->b)

Soft-keys Below the display is a row of soft-keys that can be used for any task indicated in the
associated display field (soft-key windows). Any menu utilizing these keys will
clearly indicate what they will do in that particular menu. See ’Soft-Key Windows’
on page 19 for further description.

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 1 Basic Robot Controls
1.3 Pendant

1.3.2 Display

Information in 3 Sections The display consists of three sections; status line, main section and soft-key
windows.

Status Line

Main section

Soft-key windows

Status Line The status line shows the following system information.
(1) (2) (3) (4) (5) (6) (7) (8) (9)

(1) Current menu Shows the icon for the selected menu
(2) Master device Shows the device that controls the robot, e.g. pendant, PLC
(I/O icon) etc. Visible only when an operation is being executed
(3) Robot / Run chain status Overlay icons show Error and Running status
(4) Paint supply status Overlay icons show Error and Enabled status
(5) Applicator status Overlay icons show Error and Enabled status
(6) Current Jog mode if enabled Explained in ’Jogging Modes’ on page 22
(7) Operating mode Associated with the key switch on the front panel
(8) Run chain / Motor status Icons show the status of the Run-chain and the Emergency-
stop circuits
(9) System time This serves as a visual watchdog to indicate that the pendant
has a working connection with the robot controller

Some examples of the appearance of these icons are shown in the following.

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1 Basic Robot Controls
1.3 Pendant

Overlay icons on robot icon (3), paint supply icon (4) and applicator icon (5) show
if any errors are present on these units, and if they are enabled:
Icon Description
Error icon

Robot OK and running

Robot has error and motors are off

Material supply OK

Material supply disabled

Error in material supply

Applicator OK

Applicator disabled

The Operating mode icon (7) shows the position of the key switch.
Icon Description
Automatic mode

Manual Reduced Speed mode

Manual High Speed mode

The Run chain / Motor status icon (8) shows the status of the run-chain and the
Emergency-stop circuits if engaged. If these are OK, the run status is shown
(Running, halted etc.) If a particular status is preventing the robot from starting, the
icon will show this, see examples below.
Icon Description
System error.

Emergency stop state.

Guard stop state; safety chain broken.

Emergency stop removed but Motor On button must be operated.

System is operative but motors are Off.

Motors On but program execution stopped. Also used in smaller format as an overlaid
icon to indicate that a device is ready.
Program is executing. Also used in smaller format as an overlaid icon to indicate that a
device is operating.

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 1 Basic Robot Controls
1.3 Pendant

Soft-Key Windows The soft-key windows on the bottom line show context sensitive functions that will
be available depending on current menu and system state.

In the example below, the leftmost soft-key is ‘greyed out’, meaning that it is
momentarily unavailable, but the grey text reveals the function that under different
circumstances will be available. In the third soft-key, a downward pointing
arrowhead symbol is shown. This indicates that using this soft-key will reveal a new
level. When entering this Soft-key menu, the next level of choice will appear.

At the level shown in the example below, the first button has an upward arrowhead
symbol, which indicates that it will bring the Soft-key menu system one level up
again.

In the example below, the selection that has been made is indicated by the orange
background color.

If there are more soft-key functions on the same level available than the number of
soft-key windows, there will be a scroll function available to bring about the rest,
indicated by a triple period sign (...).

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1 Basic Robot Controls
1.4 Jogging

1.4 Jogging

What is Jogging? Jogging means to move one or more robot axes using the joysticks on the pendant.

When is Jogging Jogging is possible in following operating modes:

Possible?
– Manual Reduced Speed mode
– Manual High Speed mode
In addition, all conditions for turning the motors on must have been fulfilled; live
handle activated, error acknowledged, etc.

Jogging is possible with all displayed views on the pendant, but jogging is not
possible:

– During program execution

– When the selected work object in the jogging menu is currently moving (e.g.
placed on a moving conveyor)

Joysticks Each joystick has two axes of freedom, meaning that one joystick can control two
axes at a time. Since most groups contain 3 axes, most often one joystick controls
2 axes while the other controls the third axis. The joysticks are arranged to be
operated with a thumb-grip, same way as many game controllers.

Enabling Device / Live To enable jogging, the live handle built into the underside of the grip must be
Handle operated. This can be done with one hand at a time, and the grip can be shifted to the
other hand to reduce fatigue without interrupting operations. To operate the live
handle, press to center position. Pressing too hard (panic position) disables motors
same way as when not pressing. If panic position has been engaged, the live handle
must be fully released before motors will come on again.

Jogging in Safeguarded If it is necessary to enter the safeguarded space for jogging the robot, extreme care
Space must be exercised. Always stay at a safe distance from the robot.

WARNING! When operating within the working area of the robot, the key switch
shall always be in Manual mode, and the operator shall keep the key with him so it
is not possible for other persons to take over control of the robot.

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 1 Basic Robot Controls
1.4 Jogging

Jogging Menu Select the Jogging icon on the Main menu:

The Jogging window displays the current jog settings and position of the robot.

Jog Menu-Key The orange Jog menu-key on the green keypad provides a fast way to access the
Jogging menu.

Jog menu-key

Enter-key

Back-key

When pressing the Jog menu-key, a subset of the full Jogging menu will appear on
the lower half of the display. This way the Jogging menu can be obtained in any
context, e.g. the Programming menu, with only one single click of a key. To remove
this menu, click the Jog menu-key once more, or use the Back-key.

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1 Basic Robot Controls
1.4 Jogging

Mechanical Unit Move selector to the Unit field with up/down arrows on the navigation keypad.
Selection
Browse to the specific mechanical unit (manipulator) you want to operate with
left/right arrow.

Select the mechanical unit with Enter-key.

Jogging Mode Selection To select Jogging mode, use the same method as for selecting mechanical unit, or
use the built-in click function on the joysticks, as follows:

Press and hold left joystick. By pressing the right joystick, the Jogging mode
changes to the next available mode.

The various jogging modes are described in the following.

Jogging Modes The selected jogging mode is displayed in the status bar as follows:
Icon Jogging Description Joystick direction
mode
Linear In linear jogging mode, the tool center point,
TCP, will move in straight lines parallel to the
axes of the selected coordinate system.

Reorient In reorient jogging mode, the tool center point,

TCP, will rotate around the axes of the selected
coordinate system. The TCP will only change
its orientation, not its position.

Axes 1-3 The main axes 1-3 can be jogged in this mode.
See ’Jog Axis by Axis’ on page 23.

Axes 4-6 The wrist axes 4-6 can be jogged in this mode.
See ’Jog Axis by Axis’ on page 23.

Axes 7-9 The external axes 7-9 can be jogged in this

mode. See ’Jog Axis by Axis’ on page 23.

Axes 10-12 The external axes 10-12 can be jogged in this

mode. See ’Jog Axis by Axis’ on page 23.

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 1 Basic Robot Controls
1.4 Jogging

Jog Axis by Axis Use axis by axis jogging when you need to:

– move robot out of hazardous position.

– move robot out of singularity.
– position robot axes for calibration.
All axes of the robot and connected external axes may be jogged using the joysticks.
Please check your plant or cell documentation to determine the physical orientation
of all axes.

Axes Direction The illustration shows the directions of movement of an IRB 5500 6 axis
manipulator.

-
-

Axis 4

Axis 3
Axis 2 + Axis 5 Axis 6
Axis 1
+
+

For a detailed description of your specific manipulator, see the ‘Product Manual,
Manipulator’.

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1 Basic Robot Controls
1.5 Emergency Stop Buttons

1.5 Emergency Stop Buttons

Location Emergency stop buttons are located on the operating panel and on the pendant.
More emergency stop buttons may be installed at several locations at your
installation.

Activation Activate emergency stop by pushing or pulling the emergency stop button.

Function When an emergency stop button is activated, the power supply to the motors is shut
off and program execution stops regardless of operating mode.

Emergency Situation See ’Emergency Situation’ on page 33.

24 3HNA018949-001 en Rev.00 Basic Operation, IRC5P

 2 Basic Operation
2.1 Starting the Robot

2 Basic Operation
2.1 Starting the Robot

Procedure 1. Check the following before starting the robot:

Ensure that nobody is in the manipulator working area.

Check that all entrances of the manipulator working site are safeguarded.

Check location of all emergency stop buttons for the robot.

Check that the pendant is connected to the control cabinet.

2. Apply mains power to the robot by switching the mains switch to position
On (I).

3. Wait for the following start-up sequence to be performed:

The robot performs its self-test on both the hardware and software. This test
takes approximately 5 minutes (including normally 3 minutes purging time).
The start-up progress is shown on:

The pendant display.

When the start-up process has been finished, the pendant shows the welcome
display. If an error message is displayed, see ‘Operating Manual, Trouble
Shooting’ for information.
CH1 CH2
Emy Stop Panel

Emy Stop Pendant

Emy Stop External

Emy Stop Chain

Enable Main

Enable Axis

Enable PIB

Enable SIB
The LED indicator panel.
RUN CHAIN

Mod e Stop Enable MIB

Enabling Dev ice Enable Manipulator 1

When the start-up process has been finished, the LED indicator panel shows the
General Mode Stop Enable Manipulator 2

Delay ed Stop 2 Ch. Monitoring

SYSTEM

Chain Closed Power status

Robot 1 Temp. Cabinet

DRIVE

Process - 2.1 / 2.2 Enable Chain Closed

Paint Enable Ov erpressure

HV Chain Pressurized
PROCESS

Encoder 1 - A / B

Encoder 2 - A / B
Start - 1 / 2

PIB CAN1 - MS / NS
Min. Flo w

Purge Timer

Process Status

Sy stem Status
current status. If an error should arise, indicated by a Red LED, see ’LED
COMM.

PIB CAN2 - MS / NS Cooling Fan

SPI - Int. / Ext

USER

Indicator Panel’ on page 12 for information.

USER

Display Valid

The purge indicator on the front panel.

The indicator is green, indicating that the purge sequence is completed. If
indicator is not green, check purging system.

4. Switch the mode selector to position Automatic / mode.

The Automatic mode is used for running ready-made programs in production.

5. Apply power to the motors by pressing the Motor On button (I).

The indicator lamp is steady lit when power is applied, motors are running and
ready for operation. If not steady lit, see ’Operating Panel’ on page 10.

6. If required, switch high voltage On (”I”). Only applicable for electrostatic

painting.

Ready State The robot is now up and running, and ready for running a production program.

Basic Operation, IRC5P 3HNA018949-001 en Rev.00 25

2 Basic Operation
2.2 Running a Production Program

2.2 Running a Production Program

2.2.1 The Production Menu

Getting Started Running a program in production is performed in the Production menu. To open the
menu, select the ‘Production’ icon on the Main menu of the pendant:

The Production menu will appear:

Status Info The status line of the display contains useful information for a production situation,
such as a more specific robot status (e.g. Stop type).

Job Info The main section of the display shows the current and next job, brush information
and the number of jobs in the queue.

The conveyor information has the following states:

– Initial state: Idle.

– After a program has been started: Waiting.
– After sync signal: Shows conveyor position.
– When object is dropped (paint job has been finished) the indicator returns to Idle.

Job Actions The available actions are displayed in the soft-key windows:
Start Start production or Start recovery from an error situation.
ResetErr Reset the System error state.
Enable Material supply and Applicator(s) can be enabled or disabled from this set of soft-
keys. When enabled, the soft-key will become orange colored, and the icons on
the status bar will also reflect the status of each device dynamically.
Queue Use this soft-key to enter the Job Queue menu.

26 3HNA018949-001 en Rev.00 Basic Operation, IRC5P

 2 Basic Operation
2.2 Running a Production Program

2.2.2 The Start Procedure

Start Continue the start procedure by pressing the soft-key ‘Start’ on the Production
menu:

• After a new start up of the robot, the Start Up menu appears.

• After a restart, like after an emergency stop, the Start Up Recovery menu
appears.

Start Up Menu The Start Up menu offers a choice of either:

• to start production from current position, or

• to move home and start production.
Select your alternative using up/down arrows, and press the Enter-key. Select
‘Move home’, to ensure that the robot is not colliding with the conveyor, etc.

The start up procedure will also load the standard production program framework,
set the ready-for-production outputs to the PLC and start executing the main
framework program. The system will then be ready to process the jobs in the job
queue.

Start Up Recovery Menu The Start Up Recovery menu offers a choice of either:

• to continue production from current position, or

• to unload job, move home and run the next program in the queue, or
• to unload job and run the next program in the queue.

Basic Operation, IRC5P 3HNA018949-001 en Rev.00 27

2 Basic Operation
2.2 Running a Production Program

Select your alternative using up/down arrows, and press the Enter-key. Select
‘Move home’, to ensure that the robot is not colliding with the conveyor, etc.

28 3HNA018949-001 en Rev.00 Basic Operation, IRC5P

 2 Basic Operation
2.3 Job Queue

2.3 Job Queue

2.3.1 Introduction

How it Works A Job contains a program that processes a specific workpiece (paint object). A
process can be coating the workpiece with a specific material (color). The
workpieces on the production line are waiting to be processed. Each job that has to
be carried out is placed in the job queue.

When a Program Selection sequence is completed, a job will be appended to the job
queue. When the robot is ready to process a job, it will be removed from the queue.

The Job queue is a FIFO (First In First Out) queue that may contain up to 10 jobs by
default. A job may be repeated a number of times by setting the count to a number
larger than 1, or it may be set to repeat indefinitely by setting the count value to -1.
For data entries from pendant or GUI, it is possible to add batches of jobs (more
than one workpiece with the same program and color).

Note – Program # 0 is interpreted as ‘no program’. If there is a material number

included in this job it initiates a material change if needed.
– Material # 0 is interpreted as ‘no material change’ and will not initiate a material
change. This will keep the current material loaded.
– Program numbers between 10001 and 10016 are marked as high priority, and
will be executed even if the job queue is inhibited.

Basic Operation, IRC5P 3HNA018949-001 en Rev.00 29

2 Basic Operation
2.3 Job Queue

2.3.2 The Job Queue Menu

Job Queue Menu Select the Queue icon on the Main menu:

In the Job Queue menu, all jobs waiting in the job queue will be displayed, along
with the actions laid out as soft-keys on the bottom line:

Job Queue The job queue is displayed in a scrollable table with columns for job number,
program name, material name, options associated with this job and the quantity
value (how many times this particular job shall be repeated). The first job to be
executed is on the top of the list, and the last job to arrive is at the bottom. The
queue shifts upwards automatically when a job is finished and a new job is started.

If the same job has to be carried out with an other color, the job can be edited and
the new material can be selected.

Job Queue Actions The available actions are displayed in the soft-key windows:
Append Select a job to be appended to the queue.
Edit Edit data in a job entry.
Shift Removes the job at the top of the list. Succeeding jobs are shifted up.
Insert Inserts a copy of the selected job to the first position right before the selected job
in the queue.
Erase Removes all entries in the job queue. The job queue system will be empty after
this operation.

30 3HNA018949-001 en Rev.00 Basic Operation, IRC5P

 2 Basic Operation
2.4 Stopping the Robot

2.4 Stopping the Robot

Stop Program Stop a program execution by pressing the Halt-key on the pendant.

Switch Off Control Switch motors off by pressing Motors Off button on the control cabinet.
Cabinet
Switch mains power switch to Off position on the control cabinet.

Basic Operation, IRC5P 3HNA018949-001 en Rev.00 31

2 Basic Operation
2.4 Stopping the Robot

32 3HNA018949-001 en Rev.00 Basic Operation, IRC5P

 3 Emergency Situation
2.4 Stopping the Robot

3 Emergency Situation

Action • If an emergency situation occurs, press any Emergency Stop button.

Emergency Situations An emergency situation can be:

– The robot has caused personal injury.

– The robot is at risk of causing personal injury.
– A person is spotted within the robot working area, while the robot is running.
– The robot has caused harm to mechanical equipment.
– The robot is at risk of causing harm to mechanical equipment.

Detailed Procedures Detailed procedures for releasing a trapped person, and information on how to
recover the system after an emergency stop, are found in the ‘Safety’ manual,
chapter ‘How to Deal with an Emergency’.

The Safety Manual is included in the Software and Documentation DVD following
the robot, and is also included as paper copy in the control cabinet.

Basic Operation, IRC5P 3HNA018949-001 en Rev.00 33

3 Emergency Situation
2.4 Stopping the Robot

34 3HNA018949-001 en Rev.00 Basic Operation, IRC5P

 Manual Status

Manual Status

Basic Operating Manual

IRC5P
3HNA018949-001 en Rev.00
Documents included in manual:
Chp.: Subject: File Identification: Page:
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A018949.fm 7
1 Basic Operating Manual, file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T02958 Rev.01 9

Basic Operation, IRC5P 3HNA018949-001 en Rev.00 35

Manual Status

36 3HNA018949-001 en Rev.00 Basic Operation, IRC5P

 List of Imported Graphics

List of Imported Graphics

Basic Operating Manual

IRC5P
3HNA018949-001 en Rev.00
Graphic files imported in manual:
Pg.: Illustration: Pg.: Illustration: Pg.: Illustration:
1 FrontPict.jpg @ 300 dpi 23 t0295812.wmf
9 t0295801.wmf 25 t0295803.wmf
10 t0295803.wmf 25 T0295852.jpg @ 300 dpi
10 t0295804.wmf 25 t0295810.wmf
10 t0295805.wmf 25 t0295805.wmf
10 t0295806.wmf 25 t0295808.wmf
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11 Icon_Reduced.wmf 26 T0295841.gif @ 96 dpi
11 Icon_High.wmf 27 t0295819.gif @ 150 dpi
11 Symb_Warning_g.wmf 28 t0295820.gif @ 75 dpi
12 t0295810.wmf 30 T0295850.gif @ 72 dpi
15 t0295809.wmf 31 Key_Halt.gif @ 300 dpi
15 T0295814.gif @ 300 dpi
15 T0295813.gif @ 300 dpi
15 T0295824.gif @ 150 dpi
15 Key_Navigate.gif @ 150 dpi
17 T0295813.gif @ 300 dpi
17 T0295817.gif @ 96 dpi
18 Icon_SysErr.gif @ 72 dpi
18 Icon_RobOK.gif @ 72 dpi
18 Icon_RobErr.gif @ 72 dpi
18 Icon_MatOk.gif @ 72 dpi
18 Icon_MatDis.gif @ 72 dpi
18 Icon_ErrMat.gif @ 72 dpi
18 Icon_ApplOk.gif @ 72 dpi
18 Icon_ApplDis.gif @ 72 dpi
18 Icon_Auto_TPU.gif @ 72 dpi
18 Icon_Reduced_TPU.gif @ 72 dpi
18 Icon_High_TPU.gif @ 72 dpi
18 Icon_SysErr.gif @ 72 dpi
18 Icon_EmyStop.gif @ 72 dpi
18 Icon_GuardStop.gif @ 72 dpi
18 Icon_EmyMotOn.gif @ 72 dpi
18 Icon_SysMotOff.gif @ 72 dpi
18 Icon_PrgStop.gif @ 72 dpi
18 Icon_PrgExec.gif @ 72 dpi
19 T0295830.gif @ 96 dpi
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22 T0295845.gif @ 72 dpi
22 Icon_Jog_Reor.gif @ 72 dpi
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22 Icon_Jog_Gr1.gif @ 72 dpi
22 T0295846.gif @ 72 dpi
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22 T0295847.gif @ 72 dpi
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22 Icon_Jog_ExtGr2.gif @ 72 dpi
22 T0295849.gif @ 72 dpi

Basic Operation, IRC5P 3HNA018949-001 en Rev.00 37

List of Imported Graphics

Pg.: Illustration: Pg.: Illustration: Pg.: Illustration:

38 3HNA018949-001 en Rev.00 Basic Operation, IRC5P

Contact us

ABB AS, Robotics

3HNA018949-001 en Rev.00
Discrete Automation and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 51489000

ABB Engineering (Shanghai) Ltd.

5 Lane 369, ChuangYe Road
KangQiao Town, PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666

www.abb.com/robotics