ABB Controller IRC5 With FlexPendant Eng

Product specificationControllerIRC5 with FlexPendantRobotWare 5.06

Product Specification

ControllerIRC5 with FlexPendant

RobotWare 5.063HAC 021785-001

Revision 2

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, fit-ness 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 per-mission, and contents thereof must not be imparted to a third party nor be used for any unau-thorized purpose. Contravention will be prosecuted.

Additional copies of this manual may be obtained from ABB at its then current charge.

©Copyright 2004 ABB All right reserved.

ABB Automation Technologies ABRobotics

SE-721 68 VästeråsSweden

Table of Contents

1 Description 7

1.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Flexible Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Airborne noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.2 Safety/Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.2.1 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121.3.1 Operator’s panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Motors on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Operating mode selector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.3.2 FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Example of FlexPendant window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.3.3 RobotStudioOnline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17System Builder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Configuration Editor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Program Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Event Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.3.4 RobotStudio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Simulation and offline progamming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.4 MultiMove (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Module connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20MultiMove system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Robot combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Software options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.5 Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211.5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Available memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21DRAM memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Mass memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Example of RAPID memory consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Operating requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Controller rated power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Line fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.7 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Programming environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26End position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Position types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3HAC 021785-001 Rev.2 3

Table of Contents

Program management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Editing programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Testing programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.8 Automatic Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291.8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Special routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Absolute measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.9 The RAPID Language and Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301.9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.10 Exception handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311.10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.11 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321.11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32User program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.12 Robot Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341.12.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

QuickMoveTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34TrueMoveTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Coordinate systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Coordinate systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1.13 Additional Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381.13.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Drive Module connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Simultaneous coordination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Mechanical units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Activation/Deactivation of mechanical unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Motor selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Absolute position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1.14 I/O System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411.14.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Fieldbuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Number of logical signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Number of nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41System signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41General I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42PLC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Manual functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43ABB - DeviceNet I/O units (node types) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Signal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

1.15 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471.15.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Ethernet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Serial channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3HAC 021785-001 Rev.2 4

Table of Contents

2 Specification of Variants and Options 51

2.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.2 Basic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Safety compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Mains voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Mains switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Room temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Door lock insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Cabinet connector protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Manipulator cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2.3 Control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55FlexPendant language. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55First additional language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Second additional language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56USB Flash disk interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Network connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Optional PCI cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57RS 422/485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58DeviceNet General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58DeviceNet I/O units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60DeviceNet gateway units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Power supply (for customer I/O) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Safety signals interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62IMM (Injection Mould Machines) interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Additional cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Operator’s interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Operator’s external panel cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Operating mode selector (key switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Service outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Indication lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

2.4 Drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66DC - link IRB 140, IRB 1400, IRB 2400, IRB 340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Drive units for IRB 140, IRB 1400, IRB 2400, IRB 340 (maximum three) . . . . . . . . . . . . . . . . . . . . . . 66Drive units for IRB 4400 (maximum two) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Drive units for IRB 6600, IRB 7600 (maximum two. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Drive unit capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Additional motors measurement board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Drive module cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Duty time counter (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

3HAC 021785-001 Rev.2 5

Table of Contents

3HAC 021785-001 Rev.2 6

1 Description

1.1.1 Introduction

1 Description

1.1 Structure

1.1.1 Introduction

General The IRC5 controller contains the electronics required to control the manipulator, additional axes and peripheral equipment.

Modules IRC5 is made up of the following modules:

• Drive Module, containing the drive system

• Control Module, containing the computer, operator’s panel, the mains switch, commu-nication interfaces, Flex Pendant connection, service ports and some space for cus-tomer equipment, e.g. four ABB I/O boards. The controller also contains the system software, i.e. RobotWare, which includes all basic functions for operation and pro-gramming.Furthermore, the Control Module offers 4 PCI slots for expansion boards in the com-puter.

Flexible Controller

When a Control Module is mounted on top of a Drive Module, the combination is called Flexible Controller.

Airborne noise level

Data Weight

Flexible Controller max 250 kg

Control Module 105 kg

Drive Module 110-145 kg

Data Volume

Flexible Controller 1250 x 700 x 700 mm

Airborne noise level Description

Sound pressure level out-side

< 70 dB (A) Leq (acc. to the working space Machinery directive 98/37/EEC)

3HAC 021785-001 Rev.2 7

1 Description

1.1.1 Introduction

Figure 1 The controller is specifically designed to control robots, which means that optimal performance and functionality is achieved.

Pos Name Description

A Control Module

B Drive Module

C Operator´s panel

D Protection hood All cable connections at the front, optional covered

E Controller color, rear part feet NCS 7502 B (dark grey)

F Controller color, front part, door and protection hood

NCS 2502 B (light grey)

A

B

C

D

E

F

8 Rev.2 3HAC 021785-001

1 Description

1.1.1 Introduction

Figure 2 View of the controller from the front and from above (dimensions in mm).

Pos Description

* If placed side by side, add 20 mm.

4xØ14170º

562

652

657

705*

A - A

4542

9

1232

708

722

625

1250

A A

3HAC 021785-001 Rev.2 9

1 Description

1.2.1 Standards

1.2 Safety/Standards

1.2.1 Standards

The ABB robots controlled by the IRC5 conforms to the following standards:

Safety The robot controller is designed with absolute safety in mind. It has a dedicated safety system based on a two-channel circuit which is monitored continuously. If any component fails, the electrical power supplied to the motors is cut off and the brakes engage.

Standard Description

EN ISO 12100 -1 Safety of machinery, terminology

EN ISO 12100 -2 Safety of machinery, technical specifications

EN 954-1 Safety of machinery, safety related parts of control systems

EN 60204 Electrical equipment of industrial machines

EN 775 Electrical equipment of industrial machines

EN 61000-6-4 (option) EMC, Generic emission

EN 61000-6-2 EMC, Generic immunity


IEC 204-1 Electrical equipment of industrial machines

IEC 529 Degrees of protection provided by enclosures


ISO 10218 Manipulating industrial robots, safety

ISO 9787 Manipulating industrial robots, coordinate systems and motions


ANSI/RIA 15.06/1999 Safety Requirements for Industrial Robots and Robot Sys-tems.

ANSI/UL 1740-1998 (option) Safety Standard for Robots and Robotic Equipment

CAN/CSA Z 434-03 (option) Industrial Robots and Robot Systems - General Safety Requirements

Safety function Description

Safety category 3 Malfunction of a single component, such as a sticking relay, will be detected at the next MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty section is indicated. The exe-cuting circuits are continuously monitored.This complies with category 3 of EN 954-1, Safety of machinery - safety related parts of control systems - Part 1.

Selecting the operating mode

The robot can be operated either manually or automatically. In man-ual mode, the robot can only be operated via the FlexPendant, i.e. not by any external equipment.

10 Rev.2 3HAC 021785-001

1 Description

1.2.1 Standards

Reduced speed In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min).The speed limitation applies not only to the TCP (Tool Centre point), but to all parts of the robot. It is also possible to monitor the speed of equipment mounted on the robot.

Three position enabling device

The enabling device on the FlexPendant must be used to move the robot when in manual mode. The enabling device consists of a switch with three positions, meaning that all robot movements stop when either the enabling device is pushed fully in, or when it is released completely. This makes the robot safer to operate.An additional enabling device can be connected to the safety sys-tem, for two operator safety.

Safe manual movement

The robot is moved using a joystick instead of the operator having to look at the FlexPendant to find the right key.

Over-speed protection The speed of the robot is monitored by two independent computers.

Emergency stop There is one emergency stop push button on the controller and another one on the FlexPendant. Additional emergency stop but-tons can be connected to the robot’s safety chain circuit.

Protective stop The controller has a number of electrical inputs which can be used to connect external safety equipment, such as safety gates and light curtains. This allows the robot’s safety functions to be activated both by peripheral equipment and by the robot itself.

Delayed protective stop A delayed stop gives a smooth stop. The robot stops in the same way as at a normal program stop with no deviation from the pro-grammed path. After approximately 1 second the power supplied to the motors is cut off.

Collision detection In case of an unexpected mechanical disturbance like a collision, electrode sticking, etc., the robot will stop and then slightly back off from its stop position.

Restricting the working space

SoftwareThe movement of each axes can be restrictedHardwareLimit switches can be connected to the robot´s safety chain circuit

Hold-to-run control “Hold-to-run” means that you must depress the FlexPendant start button and another button in order to move the robot. When the hold-to-run button is released the robot will stop. The hold-to-run function makes program testing safer. At reduced speed it can be activated/deactivated by a system parameter.

Fire safety The control system complies with UL’s (Underwriters Laboratory) requirements for fire safety.

Safety lamp As an option, a safety lamp mounted on the manipulator can be connected. The lamp is activated when the controller is in the MOTORS ON state.

MultiMove When several robots are connected to one Control Module, all these robots are regarded as one robot from the safety system points of view. When in manual mode all coordinated robots can be jogged simultaneously as well as only one robot or other mechani-cal unit at a time can be jogged, selected from the FlexPendant.

Safety function Description

3HAC 021785-001 Rev.2 11

1 Description

1.3.1 Operator’s panel

1.3 Operation


Control Module

Figure 3 Control Module.

Pos Name

A Mains switch and remote control of power to Drive Module(s)

B Emergency stop If pressed in, pull to release

C MOTORS ON

D Operating mode selector

E Safety chain LEDs (option)

F Service hatch

-Ethernet connection-USB connection (option)

A

B

C

D

E

F

12 Rev.2 3HAC 021785-001

1 Description


Motors on

Operating mode selector

Using a key switch, the robot can be locked in two or three different operating modes (depending on chosen mode selector).

Remote Control Both the operator’s panel and the FlexPendant can be mounted externally, i.e. sepa-rated from the cabinet and the robot can then be controlled from there.

The optional remote panel contains:

• Emergency stop

• MOTORS ON

• Operating mode selector

• FlexPendant connector

Remaining on the Control Module:

• Mains switch

• Optional safety LEDs

• Service connections

The robot can also be controlled remotely from a computer, PLC or from a cus-tomer’s panel, using serial communication or digital system signals.

MOTORS ON Operation Note

Continuous light Ready for program execution.

Fast flashing light (4Hz) The robot is not calibrated or the revolution counters are not updated.

The motors have been switched on.

Slow flashing light (1 Hz) One of the protective space stops is active.

The motors have been switched off.

Operating mode Description Signs

Automatic mode Running production

Manual mode at reduced speed Programming and setupMax. speed 250 mm/s (600 inches/min.)

Manual mode at full speed Testing at full program speedEquipped with this mode, the robot is not approved according to ANSI/UL

100%

For more information on how to operate the robot, see the Operating Manual FlexPendant and Operating manual RobotStudioOnline

3HAC 021785-001 Rev.2 13

1 Description


Drive Module

Figure 4 Drive Module.

Pos Description

A Mains isolator switch.

B Stand by lamp indicates that electronic supply is switched on by the Control Mod-ule mains switch.

C Duty Time Counter (option) accumulates the hours (up to 99999.99 h) when the motors are in operation.

A

B

C

14 Rev.2 3HAC 021785-001

1 Description

1.3.2 FlexPendant

1.3.2 FlexPendant

All operations and programming can be carried out using the portable FlexPendant (see Figure 3), the operator’s panel (see Figure 5) and RobotStudioOnline.

Figure 5 The FlexPendant is equipped with a large touch screen color display, which displays different kinds of system information, plain language messages, pictures/graphs and areas for user interaction through finger touch.

Information is presented on the display in an intuitive way. No previous program-ming or computer experience is required to learn how to use the FlexPendant. All information is in English or, if preferred, some other language (available languages, see options in chapter 2). The user can choose two alternative languages besides English without reloading RobotWare.

Pos Description

A Display

B User defined keys

C Emergency stop button

D Joystick

E Hold-to-run button (at the rear)

F Program execution keys

Feature Description

Display A 7.7” color display which displays text as well as graphical information. User input is entered by pressing menu commands, push buttons etc on the display (no stylus required). Several windows can be open simultaneously. Zoom in and out is available in many views.Many properties of the display can be set by the user for a personalized look and feel.It is possible to invert the display and joystick directions to make the FlexPendant suitable for left handed users.The FlexPendant can house powerful user applications built on Microsoft.NET technology.

A B C

DE

F

3HAC 021785-001 Rev.2 15

1 Description

1.3.2 FlexPendant

Example of FlexPendant window

Figure 6 Example of a FlexPendant window; The jogging window with the quick bar menu open at the right side.

Program execution keys

Keys for program start/stop and stepwise execution forward/backward.

User-defined keys Four user-defined keys that can be configured to set or reset an output (e.g. open/close gripper) or to activate a system input.

Hold-to-run A button which must be pressed continuously when running the pro-gram in manual mode with full speed.

Enabling device A push button which, in manual mode, when pressed halfway in, takes the system to MOTORS ON.When the enabling device is released or pushed all the way in, the robot is brought to the MOTOR OFF state.

Joystick The 3D joystick is used to jog (move) the robot manually; e.g. when programming the robot. The user determines the speed of this move-ment, large deflections of the joystick will move the robot quickly, smaller deflections will move it more slowly.

Emergency stop button

The robot stops immediately when the button is pressed in.

Feature Description

16 Rev.2 3HAC 021785-001

1 Description

1.3.3 RobotStudioOnline


Overview RobotStudioOnline is a PC software with which you work with ABB IRC5 controllers, as a complement to working from the FlexPendant.RobotStudioOnline is the software tool for installation and configuration of the ABB IRC5 controller. Efficient working on the preferred platform, use the FlexPendant for jogging, teach- in, operation, touch-up and the PC for configuration, program man-agement, on-line documentation, and remote access. The right tool for the risk task.

RobotStudioOnline acts directly on the active data in the controller. Connection to the controller can be made locally through the service port and, if the controller is equipped with the RobotWare option PC Interface, over network connection.A safe mastership handling system ensures that RobotStudioOnline can only take con-trol of a robot if this is acknowledged from the FlexPendant.

The main entry to the functionality of RobotStudioOnline is a robot view explorer. From this you select which robot to work with, in case you have several robots installed, and what parts of the system you want to work with.

RobotStudioOnline contains:

• The System Builder for creating, installing and maintaining systems

• A configuration editor for editing the system parameters of the running system

• A program editor for online programming

• An event recorder for recording and monitoring robot events

• Tools for backing up and restoring systems

• An administration tool for User Authorisation

• Other tools for viewing and handling controller and system properties

3HAC 021785-001 Rev.2 17

1 Description


1.3.3.1 Key features

System Builder The System Builder is your tool for creating, modifying and maintaining systems. You also use the System Builder to download systems from the PC to the controller.

Configuration Editor

Use the Configuration Editor to make easy and controlled changes of system parameters of the running system.From the configuration editor you view and edit the system parameters of a specific topic in a controller. The Configuration Editor has a direkt communication with the controller. This means that changes you make are applied to the controller as soon as you complete the command.

Program Editor With the Program Editor you view and edit programs loaded into the controller’s program memory. The Program Editor has built in functionality for making it easier to write the RAPID code when programming a robot.

Event Recorder With the Event Recorder you can view and save events from controllers in your robot view. You can start one Event Recorder for each controller.

Miscellaneous RobotStudio is full of other useful tools, e.g.:

• Backing up and restoring systems

• Administration tool for User Authorization

• And other tools for viewing and handling controller and system properties.E.g. monitor I/O signals

18 Rev.2 3HAC 021785-001

1 Description

1.3.4 RobotStudio

1.3.4 RobotStudio

Simulation and offline progamming

ABB’s simultation and offline programming software RobotStudio allows robot pro-gramming to be done in the office without shutting down production. It also enables robot programs to be prepared in advance, increasing overall productivity.RobotStudioOnline is a true subset of RobotStudio for IRC5.

You can save considerable time and money by using RobotStudio:

• Reduce risk by visualizing and confirming solutions and layouts

• Program new parts without interrupting production

• Optimize robot programs to increase productivity

• Generate higher part quality through creation of more accurate paths

Fore a more powerful programming tool, including off-line capability, cell layout tools and MultiMove simulation, the RobotStudio is available as a separate product.

3HAC 021785-001 Rev.2 19

1 Description

1.4.1 Introduction

1.4 MultiMove (optional)

1.4.1 Introduction

General It is possible to connect up to four Drive Modules, each running one robot or a num-ber of additional motors, to one Control Module. Each robot can control additional motors, as described in chapter 1.13 Additional Motors.

Module connections

The Drive modules are connected to the Control Module by an Ethernet cable and a safety signal cable with a maximum length of 75 m.

MultiMove system

With a MultiMove system, it is possible to operate the robots either individually or in a co-operative manner. Examples of the latter are:

• Dual robots welding on work objects rotated by an positioner

• Multiple robots together lifting a heavy object

• One robot holding a work piece while another robot is processing the work piece (typ-ically welding)

• Following combinations of robots are verified

Robot combinations

Arbitrary robot types can be combined in a MultiMove system. For IRB 340 the following limitations apply:

• With two IRB 340 in a MultiMove system, no more robots can be connected.

• The IRB 340 can not be coordinated with another robot (IRB 340 or other type).

Software options By specifying any of the RobotWare options 604-1 Coordinated robots or 604-2 Independent robots, the Control Module is prepared to connect to additional Drive modules.

Note that it is not necessary to have several Drive Modules in order to run MultiMove, as long as the mechanical units are all connected to the same drive module. One example is “manual jog”, where one additional axis is controlled from a separate task.

For further information, see Application manual - MultiMove

Note that when several robots are connected to one Control Module, the complete cell is regarded as one robot from the safety system point of view.

Note that it is not, at this time, possible to run multiple process applications simultaneously in a MultiMove system. The only exeption is RobotWare - Arc, which can be applied to any number of robots in the MultiMove system.

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1.5.1 Introduction

1.5 Memory

1.5.1 Introduction

Available memory The controller has the following memory types:

DRAM memory The DRAM memory is divided into three areas, see Figure 7.

Mass memory The mass memory is divided into four main areas.

The mass memory is used for backup, which means that when a power failure occurs or at power off, all the system specific data including the user program will be stored in the mass memory and restored at power on. A backup power system (UPS) ensures the automatic storage function.

Memory types Size Description

Fixed DRAM memory 64 MB or 256 MB1

1. 256 MB in MultiMove robots.

Working memory

Flash disk memory 256 MB Mass memory

Hard disk, optionally instead of the flash disk

20 GB Mass memory

USB flash disk interface Customer selected Removable mass memory

Areas Size

System software

System software exe-cution data

User RAPID programs 6-17 MB (when installing different options, the user program mem-ory will decrease, at most by about 1.0 MB).

Areas Size Description

Base area 64 MB40 MB

Fail Safe partition for troubleshootingPermanent code for booting

Release area 40 MB All the code for a specific release is stored

System specific data area

20 MB All the run time specific data including the user pro-gram for a system is stored at backup

User mass memory area

Can be used for storing RAPID programs, data, logs etc.

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1.5.1 Introduction

Figure 7 Available memory.

Several different systems may be installed at the same time in the controller, of which one system is the active one. Each such application will occupy another 10 MB of the mass memory for system data. The release storage area will be common as long as all installed systems are based on the same release. If two different releases are loaded, the release storage area will be doubled.

Example of RAPID memory consumption

For details on RAPID memory consumption, see RAPID reference manual - RAPID Kernel.

Pos Description

* 17 MB in MultMove robots.

DRAM memory 64 MB Mass memory 256 MB/ 20 GB

FlexPendant

System software

Data

User RAPID program6 or 17 * MB

Boot 40 MB

Release storage 40 MB

System data/user program 20 MB

Mass memory areaavailable for the user92 or > 19800 MB

Fail Safe 64 MB

Power on - restore

Power off - store

Instruction Robtarget marked (‘*’) Robtarget named

MoveL or MoveJ 312 bytes 552 bytes

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1.6 Installation

1.6.1 Introduction

General The controller is delivered with a standard configuration for the corresponding manipulator, and can be operated immediately after installation. Its configuration is displayed in plain language and can easily be changed using the RobotStudioOnline or the FlexPendant.

For a MultiMove system it is normally necessary to reconfigure the system at instal-lation time, in order to take the additional robots into account.

Operating requirements

Power supply

Controller rated power

Drive Module and Control Module together:

Requirements Description

Dust and water protection accord-ing to IEC 529

Controller electronics IP54Cooling ducts IP30

Explosive environments The controller must not be located or operated in an explosive environment according to ATEX 94/9/EC.

Ambient temperature during oper-ation

Control Module: +5oC (+41oF) to +45oC (+113oF)Control Module with option 708-2: +52oC (+125oF)Drive Module: +5oC (+41oF) to +52oC (+125oF)

Note: for 66/7600 S5C as standard withoption 708-2 +52Cº

Ambient temperature during trans-portation and storage

-25oC (-13oF) to +55oC (+131oF)

for short periods (not exceeding 24 hours): up to +70oC (+158oF).

Relative humidity Max. 95% at constant temperature

Vibration during transportation and operation

10-55 Hz: Max. ±0.15 mm

55-150 Hz: Max. 20 m/s2

Bumps during transportation and operation

Max. 100 m/s2 (4-7 ms)

Mains voltage Values

Drive Module 200-600 V, 3 phase

Control Module 230 V, 1 phase, supplied from the Drive Module

Mains voltage tolerance +10%, -15%

Mains frequency 48.5 to 61.8 Hz

Robot Rated power

IRB 140, 1400, 2400, 4400, 340

6 kVA (transformer size)

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1.6.1 Introduction

Line fusing Recommended line fusing:

Power consumption

See Product specification for respective IRB.

UPS

Configuration The controller is very flexible and can, by using RobotStudioOnline or in some cases the FlexPendant, easily be configured to suit the needs of each user:

IRB 6600, 7600 13 kVA (transformer size)

Additional Drive Module 6 or 13 kVA (transformer size)

Robot Rated power

Robot Voltage Description

IRB 140, 1400, 2400, 4400, 340

at 400-600V 3x16A slow-blowing

IRB 140, 1400, 2400, 4400, 340

at 200-220V 3x25A slow-blowing

IRB 6600, 7600 at 400-600V 3x25A slow-blowing

IRB 6600, 7600 at 200-220V 3x25A slow-blowing

Computer system backup capacity (UPS)

Value

At power interrupt 20 sec (maintenance free energy bank)

Configuration Description

Authorization Password protectionIRC5 includes an advanced user authorization system (UAS). It includes administration of users and access rights connected to user names and passwords. The same user can have different access rights for different parts of the robot system.

Most common I/O User-defined lists of I/O signals.

Instruction pick list User-defined set of instructions.

Instruction builder User-defined instructions.

Operator dialogs Customised operator dialogs.

Language All text on the FlexPendant can be displayed in several languages.

Date and time Calendar support.

Power on sequence Action taken when the power is switched on.

EM stop sequence Action taken at an emergency stop.

Main start sequence Action taken when the program is starting from the beginning.

Program start sequence Action taken at program start.

Program stop sequence Action taken at program stop.

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1.6.1 Introduction

For a detailed description of the installation procedure, see the Reference Manual System Parameters.

Change program sequence Action taken when a new program is loaded.

Working space Working space limitations.

Additional axes Number, type, common drive unit, mechanical units.

Brake delay time Time before brakes are engaged.

I/O signals Logical names of boards and signals, I/O mapping, cross connections, polarity, scaling, default value at start up, interrupts, group I/O etc (see 1.14).

Serial communication Configuration.

Configuration Description

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1.7.1 Introduction

1.7 Programming

1.7.1 Introduction

General Programming the robot can be done both from the FlexPendant or RobotStudioOnline. On the FlexPendant, instructions and arguments are picked from lists of appropriate alternatives. In RobotStudioOnline, programs are typed in in a free text format and checked for errors when “Apply Changes” is clicked (if no errors, the changes imme-diately take effect in the robot memory).

Programming environment

The programming environment can be easily customized:

• Shop floor language can be used to name programs, signals, counters, etc

• New instructions with suitable names can be created

• The most common instructions can be collected in easy-to-use pick lists

• Positions, registers, tool data, or other data, can be created

Programs, parts of programs and any modifications can be tested immediately with-out having to translate (compile) the program.

Movements A sequence of movements is programmed as a number of partial movements between the positions to which you want the robot to move.

End position The end position of a movement is selected either by manually jogging the robot to the desired position with the joystick, or by referring to a previously defined position.

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Position types A position can be defined either as:

• a stop point, i.e. the robot reaches the programmed position.

• or a fly-by point, i.e. the robot passes close to the programmed position. The size of the deviation is defined independently for the TCP, the tool orientation and the addi-tional axes.

Figure 8 The fly-by point reduces the cycle time since the robot does not have to stop at the programmed point. The path is speed independent.

Velocity The velocity may be specified in the following units:

• mm/s

• seconds (time it takes to reach the next programmed position)

• degrees/s (for reorientation of the tool or for rotation of an additional axis)

Program management

For convenience, the programs can be named and stored in different directories.

The mass memory can also be used for program storage. Programs can then be auto-matically downloaded using a program instruction. The complete program or parts of programs can be transferred to/from the network or a portable flash memory con-nected to a USB port.

The program is stored as a normal PC text file, which means that it can be edited using a standard PC.

Editing programs Programs can be edited using standard editing commands, i.e. “cut-and-paste”, copy, delete, etc. Individual arguments in an instruction can also be edited using these com-mands.

A robot position can easily be changed either by:

• jogging the robot with the joystick to a new position and then pressing the “ModPos” key (this registers the new position)

• entering or modifying numeric values

Pos Description

A User-definable distance (in mm).

(A)

Fly-by pointStop point

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1.7.1 Introduction

To prevent unauthorized personnel from making program changes, passwords can be used.

Testing programs Several helpful functions can be used when testing programs. For example, it is pos-sible to:

• start from any instruction

• execute an incomplete program

• run a single cycle

• execute forwards/backwards step-by-step

• simulate wait conditions

• temporarily reduce the speed

• change a position

For more information, see the Operating Manual FlexPendant and Operating manual RobotStudioOnline.

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1.8 Automatic Operation

1.8.1 Introduction

General A dedicated production window with commands and information required by the operator is displayed during automatic operation.

The operation procedure can be customized to suit the robot installation by means of user-defined displays and dialogs.

The robot can be ordered to go to a service position when a specific signal is set. After service, the robot is ordered to return to the programmed path and continue program execution.

Special routines You can also create special routines that will be automatically executed when the power is switched on, at program start and on other occasions. This allows you to customise each installation and to make sure that the robot is started up in a con-trolled way.

Absolute measurement

The robot is equipped with absolute measurement, making it possible to operate the robot directly when the power is switched on. For your convenience, the robot saves the used path, program data and configuration parameters so that the program can be easily restarted from where you left off. Digital outputs are also set automatically to the value prior to the power failure if this behavior has been selected.

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1.9.1 Introduction

1.9 The RAPID Language and Environment

1.9.1 Introduction

General The RAPID language is a well balanced combination of simplicity, flexibility and powerfulness. It contains the following concepts:

• Hierarchical and modular program structure to support structured programming and reuse

• Routines can be Functions or Procedures

• Local or global data and routines

• Data typing, including structured and array data types

• User defined names on variables, routines and I/O

• Extensive program flow control

• Arithmetic and logical expressions

• Interrupt handling

• Error handling (for exception handling in general, see Exception handling)

• User defined instructions (appear as an inherent part of the system)

• Backward handler (user definition of how a procedure should behave when stepping backwards)

• Many powerful built-in functions, e.g mathematics and robot specific

• Unlimited language (no max. number of variables etc., only memory limited). Built-in RAPID support in user interfaces, e.g. user defined pick lists, facilitate working with RAPID

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1.10.1 Introduction

1.10 Exception handling

1.10.1 Introduction

General Many advanced features are available to make fast error recovery possible. Charac-teristic is that the error recovery features are easy to adapt to a specific installation in order to minimise down time.

Examples • Error Handlers (automatic recovery often possible without stopping production).

• Restart on Path

• Power failure restart

• Service routines

• Error messages: plain text with remedy suggestions, user defined messages

• Diagnostic tests

• Event logging

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1.11.1 Introduction

1.11 Maintenance and Troubleshooting

1.11.1 Introduction

General The controller requires only a minimum of maintenance during operation. It has been designed to make it as easy to service as possible:

• The controller is enclosed, which means that the electronic circuitry is protected when operating in a workshop environment.

Functions The robot has several functions to provide efficient diagnostics and error reports.

Function Detail

On-line supervision Internal hardware functions

CPU temperature

CPU power levels

AC and DC voltage level

Power Supply functions

UPS capacitor status

Cooling fans

All internal communication channels (cables)

CMOS battery

Safety chains (two channel supervision)

Safety chains (function test)

Contactors and relays

Operating mode switch

Motor temperatures

Drive system: communication cable, voltage levels, tempera-tures, motor current and cable, reference quality

Measurement system: communication cable, resolver function including cables

Field bus cable (communication and power)

Field bus units (connection, status)

Program execution and resource handling

Power on Built-in self-test

Fault tracing support Computer status LEDs and console (serial channel)

Error message Displayed in plain language

The message includes the reason for the fault and suggests recovery action.

Faults and major events are logged and time-stamped.

This makes it possible to detect error chains and provides the background for any downtime. The log can be saved to file or viewed from PC tools like RobotStudioOnline, WebWare Server or any OPC client application.

Manual test Commands and service programs in RAPID to test units and functions.

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User program Most errors detected by the user program can also be reported to and handled by the standard error system. Error messages and recovery procedures are displayed in plain language.

Properties Detailed properties of hard and software in the controller are available for viewing from pendant or RobotStudio Online.

Safety chain LEDs On the panel unit (std)On the Control Module operator’s panel (optionally).

Function Detail

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1.12 Robot Motion

1.12.1 Introduction

QuickMoveTM The QuickMoveTM concept means that a self-optimizing motion control is used. The

robot automatically optimizes the servo parameters to achieve the best possible per-formance throughout the cycle - based on load properties, location in working area, velocity and direction of movement.

• No parameters have to be adjusted to achieve correct path, orientation and velocity.

• Maximum acceleration is always obtained (acceleration can be reduced, e.g. when handling fragile parts).

• The number of adjustments that have to be made to achieve the shortest possible cycle time is minimized.

TrueMoveTM The TrueMoveTM concept means that the programmed path is followed – regardless

of the speed or operating mode – even after a safeguarded stop, a process stop, a program stop or a power failure.

This very accurate path and speed are based on advanced dynamic modeling.

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Coordinate systems

Figure 9 The coordinate system, used to make jogging and off-line programming easier.

Pos Description

A Tool Center Point (TCP)

B Tool coordinates

C Base coordinates

D Object coordinates

E User coordinates

F World coordinates

(A)

Y

Z

X

Y

Z

X

Y

Z

XY

Z

X

Y

Z

X

(F)

(E)

(D)

(C)

(B)

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1.12.1 Introduction

Coordinate systems System Description

Coordinate systems RobotWare includes a very powerful concept of multiple coordinate systems that facilitates jogging, program adjust-ment, copying between robots, off-line programming, sen-sor based applications, additional axes co-ordination etc. Full support for TCP (Tool Centre Point) attached to the robot or fixed in the cell (“Stationary TCP”).

World coordinate system The world coordinate system defines a reference to the floor, which is the starting point for the other coordinate sys-tems. Using this coordinate system, it is possible to relate the robot position to a fixed point in the workshop. The world coordinate system is also very useful when two robots work together or when using a robot carrier.

Base coordinate system The base coordinate system is attached to the base mount-ing surface of the robot.

Tool coordinate system The tool coordinate system specifies the tool’s centre point and orientation.

User coordinate system The user coordinate system specifies the position of a fix-ture or workpiece manipulator.

Object coordinate system The object coordinate system specifies how a workpiece is positioned in a fixture or workpiece manipulator.

The coordinate systems can be programmed by specifying numeric values or jogging the robot through a number of positions (the tool does not have to be removed).Each position is specified in object coordinates with respect to the tool’s position and orientation. This means that even if a tool is changed because it is damaged, the old program can still be used, unchanged, by making a new definition of the tool.If a fixture or workpiece is moved, only the user or object coordinate system has to be redefined.

Stationary TCP When the robot is holding a work object and working on a stationary tool, it is possible to define a TCP for that tool. When that tool is active, the programmed path and speed are related to the work object.

Program execution The robot can move in any of the following ways:-Joint motion (all axes move individually and reach the pro-grammed position at the same time).-Linear motion (the TCP moves in a linear path).

-Circle motion (the TCP moves in a circular path).

Soft servo Soft servo - allowing external forces to cause deviation from programmed position - can be used as an alternative to mechanical compliance in grippers, where imperfection in processed objects can occur.Any motors (also additional) can be switched to soft servo mode, which means that it will adopt a spring-like behaviour.

Location If the location of a workpiece varies from time to time, the robot can find its position by means of a digital sensor. The robot program can then be modified in order to adjust the motion to the location of the part.

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Jogging The robot can be manually operated in any one of the follow-ing ways:-Axis-by-axis, i.e. one axis at a time.-Linearly, i.e. the TCP moves in a linear path (relative to one of the coordinate systems mentioned above).-Reoriented around the TCP.

It is possible to select the step size for incremental jogging. Incremental jogging can be used to position the robot with high precision, since the robot moves a short distance each time the joystick is moved.During manual operation, the current position of the robot and the additional axes can be displayed on the FlexPen-dant.

Singularity handling The robot can pass through singular points in a controlled way, i.e. points where two axes coincide.

Motion supervision The behaviour of the motion system is continuously moni-tored as regards position and speed level to detect abnor-mal conditions and quickly stop the robot if something is not OK. A further monitoring function, Collision Detection, is optional (see option RobotWare-Collision Detection).

Additional motors Very flexible possibilities to configure additional motors. Includes for instance high performance coordination with robot movement and shared drive unit for several motors.

Big inertia One side effect of the dynamic model concept is that the system can handle very big load inertias by automatically adapting the performance to a suitable level. For big, flexible objects it is possible to optimise the servo tuning to minimise load oscillation.

System Description

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1.13.1 Introduction

1.13 Additional Motors

1.13.1 Introduction

General With the standard drive module, the robot can control up to three additional motors (two for IRB4400/6600/7600). These motors are programmed and moved in the same way as the robot’s motors. See Figure 10.

Figure 10 Standard Drive Module.

An additional drive module can be connected for control of up to eight or nine addi-tional motors. Further drive modules (max 4 in total) makes it possible to control up to 36 motors. See Figure 11.

Figure 11 Additional Drive Module.

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Drive Module connection

Any IRB Drive Module can be connected to the Control Module, independent of the basic robot equipment. An additional Ethernet board (option 710-1) in the Control Module is the only additional hardware required. The Drive Modules are from start configured with 4-6 drives (see below) but can be configured for more motors according to the specification form for the respective robot. The Drive Modules are complete with power distribution, transformers, dual contactor circuits, cooling, power supply and axis computer.

Drive Module

Note that an additional Drive Module for additional motors reduces the maximum number of additional robots to two. See MultiMove (optional) on page 20.

IRB 140-1400 Drive Module

Basic specification 3 x A drive

3 x B drive

IRB 2400 Drive Module

Basic specification 2 x E drive

2 x C drive

2 x B drive

IRB 340 Drive Module

Basic specification 3 x E drive

1 x C drive

IRB 4400/940 Drive Module

Basic specification 3 x T drive

3 x G drive

IRB 6600/7600 Drive Module

Basic specification 3 x V drive

3 x W drive

Drive unit type

Continous current(Amp rms)

Max current(Amp rms)

Voltage to motor(V rms)

Max bus voltage(V DC)

W 30 55 400-480* 790

V 14.5 25 400-480* 790

T 25 38 260 430

G 16.5 26 260 430

E 12 19 260 430

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1.13.1 Introduction

*) Depending on line voltage

Simultaneous coordination

Up to 12 motors, including the robot, can be active at the same time in the same motion task. The robot motion can be simultaneously coordinated with for example, a linear robot carrier and a work piece positioner.

Mechanical units The additional motors can be grouped into mechanical units to facilitate, for exam-ple, the handling of robot carriers, workpiece manipulators, etc. All motors within a mechanical unit must be connected to the same drive module.

Activation/Deactivation of mechanical unit

A mechanical unit can be activated or deactivated to make it safe when, for example, manually loading a workpiece on the unit. In order to reduce investment costs, any motors that do not have to be active at the same time, can share the same drive unit.

Motor selection For motor selection, see the Product Specification Motor unit MU10, MU20, MU30.Motor dimensions according to 3HAC 023209-001, available on ABB Library.

Absolute position Absolute position is accomplished by battery-backed resolver revolution counters in the serial measurement board (SMB). Encapsulated SMB units are also described in the Product Specification Motor Units.

C 9 12 260 430

B 5.5 6.7 260 430

A 2 3.3 260 430

Drive unit type




Max bus voltage(V DC)

For more information on how to install an additional motor, see the Application manual – additional axes. This manual also specifies necessary resolver data.

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1.14.1 Introduction

1.14 I/O System

1.14.1 Introduction

Fieldbuses There is a choice of different fieldbus types (option):

This makes it possible to mount the I/O units either inside the cabinet or outside the cabinet with a cable connecting the I/O unit to the cabinet.

Multiple fieldbuses can be installed in parallel with both master and slave function-ality.

For all bus types, commercially available third party slave boards can be used.

For DeviceNet, a number of different input and output units are available from ABB, see table on page 43 and Specification of Variants and Options on page 51.

Gateway In addition to above master/slave units, there is a choice of optional gateway units acting as translator between DeviceNet and the respective fieldbus.

• Allen-Bradley RIO

• Profibus DP

• Interbus

Number of logical signals

The maximum number of logical signals is 1024 in total for all installed field buses (inputs or outputs, group I/O, analog and digital).

Number of nodes A maximum of 20 I/O units (nodes) may be connected to each field bus and a maxi-mum of 40 units (nodes) may be connected in the system totally.

System signals Signals can be assigned to special system functions such as program start, so as to be able to control the robot from an additional panel or PLC. Several signals can be given the same functionality.

Option Description

DeviceNet PCI card certified by ABB included

Profibus DP PCI card certified by ABB included

Interbus PCI card certified by ABB included

Digital inputs Digital outputs Analog outputs

Motors On Auto on TCP Speed

Motors On and Start Blocked I/O TCP Speed Reference

Motors Off Cycle On

Load and Start Emergency Stop

Interrupt Execution Error

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General I/O The inputs and outputs can be configured to suit your installation:

• Each signal and unit can be given a name, e.g. gripper, feeder

• I/O mapping (i.e. a physical connection for each signal)

• Polarity (active high or low)

• Cross connections

• Up to 16 digital signals can be grouped together and used as a single signal when, for example, entering a bar code

• Sophisticated error handling

• Selectable “trust level” (i.e. what action to take when a unit is “lost”)

• Program controlled enabling/disabling of I/O units

• Scaling of analog signals

• Filtering

• Pulsing

• TCP-proportional analog signal

• Programmable delays

• Virtual I/O (for forming cross connections or logical conditions without need for the physical hardware)

• Accurate coordination with motion

PLC The robot can function as a PLC by monitoring and controlling I/O signals:

• I/O instructions are executed concurrent to the robot motion.

• Inputs can be connected to trap routines. When such an input is set, the trap routine starts executing. Following this, normal program execution resumes. In most cases, this will not have any visible effect on the robot motion, as long as a reasonable num-ber of instructions are executed in the trap routine.

• Background programs (for monitoring signals, for example) can be run in parallel with the actual robot program. This requires Multitasking option, see Product Specification RobotWare Options.

Start Motors Off State

Start at main Motors On State

Stop Motors Off

Stop at end of Cycle Motors On

Stop at end of Instruction Motion Supervision On

Reset Execution Error signal Motion Supervision Trig-gered

Reset Emergency Stop Power Fail Error

System Restart Path Return Region Error

Runchain Ok

Digital inputs Digital outputs Analog outputs

For more information on system signals, see the Reference Manual System Parameters.

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Manual functions Manual functions are available to:

• List all the signal values

• Create your own list of your most important signals

• Manually change the status of an output signal

ABB - DeviceNet I/O units (node types)

Figure 12 Example of a DeviceNet bus.

The table shows the maximum number of physical signals that can be handled by each unit.

Pos Description

A Terminator

B Trunk line

C Drop line

D Tap

E Zero drop

F Node

G Short drop

H T-connector

A

IRC5

B

E

A

G

F

C

F

F

F

F

D

F

FF F

C C

H

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1.14.1 Introduction

Data rate for ABB DeviceNet I/O units is fixed at 500 Kbit/s.

Maximum four ABB DeviceNet I/O or gateway units can be mounted in the Control Module.

Power supply 24 V DC is available as option. Data according to table.

Type of unit DSQCOption no.

In OutVoltage inputs

Voltage output

Current output

Power supply

Digital I/O 24 VDC

328A 716-1 16 16 Internal/External1

1. The digital signals are supplied in groups, each group having 8 inputs or outputs

Analog I/O 355A 719-1 4 3 1 Internal

AD Combi I/O 327A 717-1 16 16 2 Internal/External1

Relay I/O 332A 718-1 16 16 Internal/External2

2. To calculate the number of logical signals, add 2 status signals

Allen-Bradley Remote I/O gateway

350A 721-1 1282 128

Interbus gate-way

351A 722-1 642 64

Profibus DP gateway

352A 720-1 1282 128

Encoder inter-face unit

377A 725-1 1

Type Name Data

Option 727-1DSQC 608

Option 727-22 x DSQC 608

Customer I/O power supply

Output voltage 24 V DC -0% +10%. 0 V directly grounded to chassis.Rated continuous load 8AOutput over current protection <12AOutput over voltage protection <31.2VOutput hold-up >20msOutput noise/ripple <200mV p-p

Option 728-1DSQC 634

DeviceNet power supply

Output voltage 24 V DC -1% +5%, galvanic iso-lated from chassis.Rated continuous load 4AOutput over load protection <100VAOutput over voltage protection <29VOutput hold-up>20msOutput noise/ripple <25V p-p

Fulfils Limited Power Source NEC Class 2 requirement

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1.14.1 Introduction

The DSQC 634 minimize the risk for ground loops due to potential differences when e.g. connecting multiple masters to one bus.

Signal dataDigital inputs (option 716-1, 717-1, 718-1)

Values

24 V DC Optically-isolated

Rated voltage 24 V DC

Logical voltage levels “1” 15 to 35 V“0” -35 to 5 V

Input current at rated input voltage 6 mA

Potential difference max. 500 V

Time delays hardware 5-15 ms

software ≤ 3 ms

Time variations ± 2 ms

Digital outputs (option 716-1, 717-1)

Values

24 V DC Optically-isolated short-circuit protected, supply polarity protection

Voltage supply 19 to 35 V

Rated voltage 24 V DC

Logical voltage levels “1” 18 to 34 V“0” < 7 V

Output current max. 0.5 A


Time delays hardware ≤ 1ms

software ≤ 2ms

Time variations ± 2 ms

Relay outputs (option 718-1) Values

Single pole relays with one make contact (normally open)

Rated voltage 24 V DC, 120 VAC

Voltage range 19 to 35 V DC24 to 140 V AC

Output current max. 2 A

Potential difference max. 500V

Time intervals hardware (set signal) typical 13 ms

hardware (reset signal) typical 8 mssoftware ≤ 4 ms

Analog inputs (option 719-1) Values

Voltage Input voltage ±10 V

Input impedance >1 Mohm

3HAC 021785-001 Rev.2 45

1 Description

1.14.1 Introduction

Resolution 0.61 mV (14 bits)

Accuracy ±0.2% of input signal

Analog outputs (option 719-1) Values

VoltageOutput voltage ±10 V

Load impedance min. 2 kohm


CurrentOutput current 4-20 mA

Load impedance min. 800 ohm

Resolution 4.88 µA (12 bits)

Accuracy ±0.2% of output signal

Analog outputs (option 717-1) Values

Output voltage (galvanically isolated) 0 to +10 V

Load impedance min. 2 kohm


Accuracy ±25 mV ±0.5% of outputvoltage


Time intervals hardware ≤ 2.0 ms

software ≤ 4 ms

Analog inputs (option 719-1) Values

46 Rev.2 3HAC 021785-001

1 Description

1.15.1 Introduction

1.15 Communication

1.15.1 Introduction

Ethernet The controller has two Ethernet channels which both can be used at 10 Mbit/s or 100 Mbit/s. The communication speed is set automatically.

Figure 13 Point-to-point communication

The communication includes TCP/IP with network configuration possibilities like:

• DNS, DHCP etc. (including multiple gateway)

• Network file system access using FTP/NFS client and FTP server

• Control and/or monitoring of controllers over OPC or by Windows applications built with PC SDK (part of Robot Application Builder)

• Boot/upgrading of controller software via the network or a portable PC

• Communication with RobotStudio, see section 1.3.4 RobotStudio

Pos Description

A Temporary EthernetB Permanent Ethernet or serial

(A)

(B)

3HAC 021785-001 Rev.2 47

1 Description

1.15.1 Introduction

Figure 14 Network (LAN) communication.

Serial channel The controller has one (optional three) serial channel RS232 for permanent use which can be used for communication point to point with printers, terminals, com-puters and other equipment.The serial channel can be used at speeds up to 115 Kbit/s.

HUB

48 Rev.2 3HAC 021785-001

1 Description

1.15.1 Introduction

The RS232 channel can be converted to RS422 or RS485 with an optional adapter. The following modes of operation are supported:

• RS422

• RS485 4-wire (full duplex, Master)

• RS485 2-wire (half duplex)

Note: Synchronous (clocked) mode is NOT supported.

3HAC 021785-001 Rev.2 49

1 Description

1.15.1 Introduction

50 Rev.2 3HAC 021785-001

2 Specification of Variants and Options

2.1.1 Introduction


2.1 Structure

2.1.1 Introduction

General The different variants and options for the controller are described below.

The same option numbers are used here as in the respective Specification form for any IRB.

For details about manipulator options, see Product Specification for the respective IRB. For software options, see Product Specification RobotWare 5.0.

3HAC 021785-001 Rev.2 51


2.2.1 Introduction

2.2 Basic

2.2.1 Introduction

Safety compliance

Mains voltage The IRC5 controller can be connected to a rated voltage of between 200 V and 600 V, 3-phase and protective earthing. A voltage fluctuation of +10% to −15% is per-mitted. The power cable is connected to the Drive Module via an industrial connec-tor. The cable part of the connector is supplied.

The Control Module is supplied with 230V from the Drive Module.

The options below indicate the connection and labelling at delivery. All robots including servo transformer can be switched to another mains voltage if e.g. a line builder uses a different voltage than the end customer.

Option Description

429-1 UL/CSA The robot and the control system are certified by Under-writers Laboratories to comply with the Safety Standard ANSI/UL 1740-1998 “Industrial Robots and Robotic Equipment” and CAN/CSA Z 434-94. Law for UL/CSA certification is required in some US states and Canada.UL (UL listed) means certification of the complete robot product.The option is visualized by a “UL” label attached to the cabinet.

129-1 EU - Electromagnetic Compatibility

The robot and the control system comply with the Euro-pean Union Directive“Electromagnetic Compatibility” 89/336/EEC.The option consists of an additional line filter located in the Drive Module. A certifying document “Declaration by the manufacturer” is also supplied which tells the machine integrator that the robot is prepared for CE marking.Not available for controllers connected to 600 V.

Option Voltage

Servo transformer

IRB 140

IRB 1400

IRB 2400

IRB 4400

IRB 340

IRB 6600

IRB 7600

769-7 200V X X X X X X X

769-1 220V X X X X X X X

769-2 400V X X X X X - X

769-3 440V X X X X X - X

769-4 480V X X X X X - -

769-5 500V X X X X X X X

769-6 600V X X X X X X X

52 Rev.2 3HAC 021785-001


2.2.1 Introduction

Mains switch The power is controlled from the Control Module while the Drive Module switch acts as an isolator. The Drive Module switch can be either of rotary type or flange disconnect type.

Room temperature

Door lock insert The same type of lock insert is valid for both Control Module and Drive Module.

Below options add a replacement insert. Standard is mounted at delivery.

Option Description

742-1 Rotary switch in accordance with the standard in chapter 1.2 and IEC 337-1, VDE 0113.The Controller Module switch is rated 16A while the Drive Module switch is rated 40A.Customer fuses at the distribution panel are required for cable short circuit protection.

743-1 Circuit breaker for rotary switch. A circuit breaker for short circuit protection of mains cables in the Drive Module. Circuit breaker approved in accor-dance with IEC 898, VDE 0660.

744-1 Door interlock for rotary switch.

Some standards, i.e. EN 60206, do not recommend longer power cable than 3 m without fuse protection at the distribution panel. If such protection exists, the option circuit breaker is not necessary.

Option Temperature Description

708-1 Room temperature up to 45oC (113oF)

Standard design of the Control Module and Drive Module.

708-2 Room temperature up to 52oC (125oF)

Internal forced air circulation in the Control Module, increased fan capacity in the IRB 6600/IRB 7600 Drive Module.

Option Description

739-1 Standard, coin proof type, Screw driver required to operate

Option Description

739-2 Square 7 mm outside

739-3 EMKA DB

739-4 Cylinder 3524

739-5 Doppelbart

3HAC 021785-001 Rev.2 53


2.2.1 Introduction

Cabinet connector protection

Manipulator cables

The manipulator cables consists of two cables.

Option Connector Description

741-1 One connector cover The Drive Module connectors are protected.

741-2 Two connector covers Both Control Module and Drive Module connec-tors are protected.

Cable Type Description

Motor cable Industrial connector type in both ends exept for IRB 140 where the manipulator end has internal connection.

Measurement cable Circular connector type in both ends exept for IRB 140 where the manipulator end has internal connection.

Option Description Remarks

210-1 3 m only IRB 340

210-2 7 m

210-3 15 m

210-4 22 m Not for IRB 140

210-5 30 m Not for IRB 140

211-2 22m Only IRB 140

211-3 30 m Only IRB 140

54 Rev.2 3HAC 021785-001


2.3.1 Introduction

2.3 Control module

2.3.1 Introduction

FlexPendant Color graphic pendant with touch screen. Holder for mounting at the Control Mod-ule, at the cell fence or similar is included.

FlexPendant language

Three user interface languages can be stored in the pendant. English is always avail-able, the first and second additional language can be selected. The user can switch between the languages with a restart of the FlexPendant.

First additional language

Option Controller Description

700-1 No control module When the robot is controlled from another con-troller in a Multi Move system, this option is selected.

700-2 Flexible Controller The control system consists of one Control Mod-ule and one Drive Module. They are delivered in one piece with inter cabling pre-installed.

Option Description

701-1 With 10 m cable

701-3 With 30 m cable With this option the FlexPendant is delivered with a 10 m cable and comes with a separate 30 m cable. The cable replacement is an easy operation.

702-1 Connector plug The option consists of a jumper connector to close the safety chains. This is required if a FlexPendant is not connected.

Option Language

644-1 French

644-2 German

644-3 Spanish

644-4 Italian

644-5 Chinese

644-6 Portugese

644-7 Dutch

644-8 Swedish

644-9 Danish

644-10 Czech

644-11 Finnish

3HAC 021785-001 Rev.2 55


2.3.1 Introduction

Second additional language

Memory

USB Flash disk interface

644-12 Korean

644-13 Japanese

Option Language

Option Language

645-1 French

645-2 German

645-3 Spanish

645-4 Italian

645-5 Chinese

645-6 Portuguese

645-7 Dutch

645-8 Swedish

645-9 Danish

645-10 Czech

645-11 Finnish

644-12 Korean

644-13 Japanese

Option Memory Description

705-1 Hard disc The standard 256 MB flash drive is replaced by a hard drive 20 GB or larger.

Option Description

706-1 In addition to the computer port there is an external connector located at the operator panel (not available on remote operator panel).

Note that no other USB function than flash disk is supported.

56 Rev.2 3HAC 021785-001


2.3.1 Introduction

The following USB Flash drive types are verified:

Network connection

Optional PCI cards

Four slots are available for different usage.

Disk types Values

San Disk Cruzer Mini 128/256 MB

Iomega Mini 128 MB

Option Description

707-1 Ethernet on connector plate

As an addition to the connector on the computer front, there is an optional RJ45 connector (IP 54 protected) on the connector plate.

Corresponding customer part is not included.Harting type 09 45 115 1100 00 (complete kit) is recommended.

Option Description

709-1 DeviceNet m/s single channel

Required when ABB I/O and gateway units are to be used as well as 3rd party DeviceNet units. The hardware consists of a PCI board with a 5-pole open DeviceNet connector at the front. The DeviceNet bus can be configured for 125/250/500 Kbit/s. The highest speed, which has to be used for ABB units, maximize the trunk cable length to 100 m. For more information, see Appli-cation manual - DeviceNet.

Occupies one PCI slot.

709-2 DeviceNet m/s dual channels

Occupies two PCI slots.

710-1 Communication (Ethernet) card to other robot(s) in a Multi Move application or to additional drive units in separate Drive Module.Occupies one PCI slot.

711-1 Profibus DP m/s The hardware of the Profibus DP field bus con-sists of a master/slave unit, DSQC 510/637. The signals are connected to the board front (two 9-pole D-sub).Occupies one PCI slot.

The slave units can be I/O units with digital and/or analogue signals. They are all controlled via the master part of the DSQC 510/637 unit.The slave part of the DSQC 510/637 is normally controlled by an external master on a separate Profibus DP network. The slave part is a digital input and output I/O unit with up to 512 digital input and 512 digital output signals.

3HAC 021785-001 Rev.2 57


2.3.1 Introduction

RS 422/485

DeviceNet General

Up to 4 DeviceNet I/O or Gateway units can be mounted inside the Control Module. Further units need to be mounted in an encapsulation elsewhere.

285-1 Profibus DP M/S CFG Tool

The tool consists of software for a standard PC. The tool creates a bus configuration, which is used in the robot controller.

Note: This tool is NOT needed for configuration and use of other channels than the DSQC 510/637 master channel.

712-2 Interbus m/s optical fibre

The hardware of the Interbus field bus consists of a Master/Slave unit (DSQC512/529). The master and the slave units are two separate boards con-nected by a flat cable.

Occupies two PCI slots.The slave units can be I/O units with digital and/or analogue signals. They are all controlled by the master part of the DSQC512/529 unit.

The slave part of the DSQC512/529 unit is nor-mally controlled by an external master

on a separate Interbus network. The slave part is a digital in- and output I/O unit with up to 160 dig-ital input and 160 digital output signals.

712-1 Interbus m/s copper wire (9-pole D-sub con-nections)

185-1 Interbus M/S CFG Tool The tool consists of software for a standard PC. The tool creates a bus configuration, which is used in the robot controller.Note: This tool is needed for configuration of both master and slave channel of DSQC 512/529.

713-1 Multiple serial ports Serial communication card DSQC 614 with two RS232 ports, COM2 and COM3.Occupies one PCI slot

Option Description

Option Decription

714-1 RS232 to RS422/485 converter

An adapter plug added to the serial port COM1. The RS422/485 enables a more reliable point to point communication (differential) over longer distance, fromRS232 = 15 m to RS422/485 = 120 m.

58 Rev.2 3HAC 021785-001


2.3.1 Introduction

Option Description

730-1 DeviceNet on front One 5-pole female connector for option 709-1 in accordance with ANSI.

Corresponding customer part is not included.

Brad Harrison type 1A5006-34 or ABB part number 3HAC 7811-1 is recom-mended.

3HAC 021785-001 Rev.2 59


2.3.1 Introduction

DeviceNet I/O units

The customer cables are connected directly to screw terminals on the I/O units.

Figure 15 Dimensions for I/O units.

DeviceNet gateway units

The customer cables are connected directly to connectors on the gateway units.

Option Description

716-1 Digital 24 VDC I/O 16 inputs/16 outputs

717-1 AD Combi I/O 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V)

718-1 Digital I/O with relay outputs 16 inputs/16 outputsRelay outputs to be used when more cur-rent or voltage is required from the digital outputs. The inputs are not separated by relays.

719-1 Analog I/O 4 inputs: ± 10V 4 outputs: 3x ± 10V, 1x4-20mA

Pos Description

A EN 50022 mounting rail

(A)

195

203 49

Option Description

720-1 Profibus DP (DSQC 352A) Up to 128 digital inputs and 128 digital out-puts can be transferred serially to a PLC equipped with a Profibus DP interface. The bus cable is connected directly to the DSQC 352 (one 9-pole D-sub).

60 Rev.2 3HAC 021785-001


2.3.1 Introduction

721-1 Allen-Bradley Remote I/O (DSQC 350A)

Up to 128 digital inputs and outputs, in groups of 32, can be transferred serially to a PLC equipped with an Allen Bradley 1771 RIO node adapter. The bus cable is connected directly to the DSQC 350 (two 4-pole Phoenix connectors included).

722-1 Interbus (DSQC 351A) Up to 64 digital inputs and 64 digital outputs can be transferred serially to a PLC equipped with an InterBus interface. The bus cables are connected directly to the DSQC 351A (two 9-pole D-sub).

726-1 Encoder interface unit for conveyor tracking (DSQC 377A)

This option is required for:

• Conveyor Tracking (RW option 606-1) which makes the robot follow a work object on a moving conveyor.

• Sensor Synchronization (RW option 607-1) adjusts the robot speed to an external moving device (e.g. a press or conveyor) with the help of a sen-sor.

• PickMaster conveyor tracking appli-cations.

The customer encoder and synchronization switch cables are connected directly to the DSQC377 (one 16-pole Phoenix connector included).The encoder must be of 2 phase type for quadrate pulses, to enable registration of reverse conveyor motion, and to avoid false counts due to vibration etc. when the con-veyor is not moving.Output signal: Open collector PNP outputVoltage: 10 - 30 V (normally supplied by 24 VDC from DSQC 377A)Current: 50 - 100 mAPhase: 2 phase with 90 drgree phase shiftDuty cycle: 50%Following encoder is verified:Lenord & Bauer GEL 262

Option Description

3HAC 021785-001 Rev.2 61


2.3.1 Introduction

Figure 16 Dimension for gateway units.

Power supply (for customer I/O)

Safety signals interface

Pos Description

A EN 50022 mounting rail

(A)

170

115 49

Option Description

727-1 24 V 8 Amps for bus and process supply

727-2 24 V 16 Amps for bus and process supply

728-1 24 V 4 Amps for DeviceNet bus supplyFulfils Limited Power Source NEC Class 2 requirement

Option Connection Description

731-1 Internal connection The signals are connected directly to screw ter-minals at the panel board inside the cabinet

731-2 External connection The signals are connected via a 64-pole standard industrial connector in accordance with DIN 43652. The connector is located at the foot of the module.Corresponding customer part is included.

62 Rev.2 3HAC 021785-001


2.3.1 Introduction

IMM (Injection Mould Machines) interface

There are three different standards used for the interface between an injection moul-ding machine and a robot:

Additional cables Additional cables for the different standards are available.

To facilitate the configuration of the IO-interface in the controller, specific IO-con-figuration files will be available on the RobotWare CD in the Utility directory.

The pre-defined signals for Euromap need one digital I/O board, which has to be ordered with the robot. For additional devices (gripper, conveyor, etc.) additional boards have to be ordered.

For the signal “Mould area free” from the robot to the injection moulding machine a position switch on axis 1 is required. It has to be ordered with the robot.

Figure 17 Additional converter box outside the cabinet plugged on the Euromap 67 connector.

Option Type Description

671-2 Euromap 67 is the actual standard in Europe which offers double channel security from injection moulding machine. The robot interface for Europe 67 im implemented in the standard IRC5 cabinet with a Euromap connector mounted on the connector board.

671-1 Euromap 12 is used for older injection moulding machines which offer only single channel security. To adapt to a robot an additional converter box outside the cabinet is plugged on the Euromap 67 connector. See Figure 17

671-3 SPI (Society of Plastics Indus-try)

is the corresponding standard in US. Also in this case an additional converter box outside the cabinet is plugged on the Euromap 67 connector. See Figure 17.

Option Description

673-1 10 m

673-2 15 m

Em67

Em12

SPI

IRC5Controller

3HAC 021785-001 Rev.2 63


2.3.1 Introduction

Operator’s interface

The operator‘s panel can be installed in different ways.

Figure 18 External control panel mounted in a box.

Operator’s external panel cables

Operating mode selector (key switch)

The three modes types do not comply with UL safety standards.

Additional contact means two extra dry contacts for customer usage.

Option Standard Description

733-1 Standard On the front of the cabinet.

733-2 External Mounted in a box. See Figure 18.

733-3 External To be mounted in a separate operator’s unit (enclo-sure not supplied).

Option Length

734-1 15 m

734-2 22 m

734-3 30 m

Option Standard Description

735-1 Standard 3 modes: manual, manual full speed and automatic.

735-2 Standard 2 modes: manual and automatic.

735-3 Additional contact 3 modes manual, manual full speed and automatic.

735-4 Additional contact 2 modes: manual and automatic.

64 Rev.2 3HAC 021785-001


2.3.1 Introduction

Figure 19 Two extra dry contacts for customer usage.

Service outlet Any of the following standard outlets with earth fault protection can be chosen for service purposes. Max load is 200W. The outlet is located at the connector plate.

Indication lamps External indication of the safety signals in addition to the internal LEDs at the panel board. The LEDs are located at the control module operator panel (not available on the remote operator panel).

2 4 85 1

-S21.1.X1 3 2 1 4 7 6 5 8

OPTION

ModeSelector21.1

-245

-244

-243

-246

-241

-240

-239

-242

EX

T.A

UTO

2

EX

T.M

AN

2

EX

T M

AN

FS

2

EX

T.C

OM

MO

N2

EX

T.A

UTO

1

EX

T.M

AN

1

EX

T M

AN

FS

1

EX

T.C

OM

MO

N1

18 22 24 14 16 2010126

17 13

Option Outlet Description

736-1 230 V outlet in accordance with DIN VDE 0620

single socket suitable for EU countries

736-2 120 V outlet in accordance with American standard

single socket, Harvey Hubble.

Option Status Description

737-1 Status LEDs in front

3HAC 021785-001 Rev.2 65


2.4.1 Introduction

2.4 Drive module

2.4.1 Introduction

General The Drive Module includes, besides of the drive system for a 4-6 axes robot, also equipment to control additional motors, up to two single drive units for IRB 940, IRB 4400, IRB 6600, IRB 7600, and up to three single drive units for IRB 140, IRB 1400, IRB 2400, IRB 340.

DC - link IRB 140, IRB 1400, IRB 2400, IRB 340

The DC - link capacity is increased so that additional drive units can be handled.

This option will thus minimize the effort of retrofitting additional motors.

Drive units for IRB 140, IRB 1400, IRB 2400, IRB 340 (maximum three)

Drive units for IRB 4400 (maximum two)

Drive units for IRB 6600, IRB 7600 (maximum two

Option Description

766-1 Prepared for additional drive units

Note! The option is not required if any of the options 753-771 below is selected.

Options Description

753-1, 754-1, 755-1 Drive unit C

753-2, 754-2, 755-2 Drive unit T

753-3, 754-3, 755-3 Drive unit U

Options Description

770-1, 771-1 Drive unit C

770-2, 771-2 Drive unit T

770-3, 771-3 Drive unit U

Options Description

770-4, 771-4 Drive unit W

66 Rev.2 3HAC 021785-001


2.4.1 Introduction

Drive unit capacity

*) Depending on line voltage and robot type. Bus voltage is 480V except forIRB6600 with 400V mains voltage which has bus voltage 400V.

Additional motors measurement board

When a drive unit is mounted, an additional connector for a second measurement cable is also included. The cable is ordered separately (786-x for IRB 66/7700). Encapsulated measurement board is selected from the Motor unit specification.

For users who want to put the board in own equipment, there is an option available.

Drive module cables

The Drive Module is connected to the Control Module by the means of Ethernet Communication and safety signals. The options are intended for MultiMove system or distributed additional drive modules.

Duty time counter (DTC)

In addition to the optional hardware DTC there is also a software DTC (see SIS). This function displays the operating time on the FlexPendant.

Drive unit type




Max bus DC voltage

W 30 55 400-480* 790

U 36 55 260 430

T 25 38 260 430

C 9 12 260 430

Option Description

757-1 Serial measurement board as separate unit for external assembly

Option Description

761-1 Cable length 4 m to be used when two Drive Modules are stacked with the Control Module on top.

761-3 Cable length 30 m. The cable can easily be shortened by means of normal installation tools

CMDMDM

(4 m)

CMDM DM

(30 m)

Option Description

767-1 Indicates the operating time for the manipulator (released brakes).

3HAC 021785-001 Rev.2 67


2.4.1 Introduction

68 Rev.2 3HAC 021785-001

Index

A

absolute measurement, 29additional Motors, 38Allen-Bradley Remote I/O, 44, 61analog signals, 42authorization, 18, 24automatic operation, 29

B

backup, 21bumps, 23

C

Cabinet connector protection, 54collision detection, 11communication, 47computer system backup, 24concurrent I/O, 42configuration, 24configuration editor, 18connection, Ethernet, 12connection, FlexPendant, 7connection, network, 57connection, USB, 12control module, 7cooling device, 7coordinate systems, 35cross connections, 42

D

diagnostics, 32digital signals, 42DRAM memory, 21drive module, 7, 14drive units, 66

E

editing, position, 28editing, programs, 27editing, system parameters, 17Emergency, 13emergency stop, 11emergency stop button, 15enabling device, 11, 16Encoder, 61Encoder interface unit, 44event recorder, 17exception handling, 31explosive environments, 23

F

fire safety, 11flash disk memory, 21FlexPendant, 15, 26fly-by point, 27

H

hold-to-run control, 11humidity, 23

I

I/O system, 41I/O units, 44installation, 23Interbus, 44, 61Interbus Slave, 41interrupt, 41

J

joystick, 15, 16

K

key features, 18

L

language, 24

M

mains switch, 53mains voltage, 52maintenance, 32mass memory, 21memory, available, 21memory, controller’s program, 18memory, extended, 21motion, 34MuliMove, 20MultiMove, 11, 19Multitasking, 42

N

noise level, 7

O

operating mode selector, 13operating modes, 13operating requirements, 23operation, 12operator’s external panel cables, 64operator’s panel, 12options, 51over-speed protection, 11

P

password, 24PLC functionality, 42position fixed I/O, 42position programming, 27production window, 29Profibus, 57, 58, 60Profibus DP, 41program editor, 18program, without interrupting production, 19programming, 26

3HAC 021785-001 Rev.2 69

Index

protective stop, 11protective stop, delayed, 11

R

RAPID Language, 30Reduced speed, 11RobotStudio, 19RobotStudioOnline, 17, 26

S

safe manual movements, 11safety, 10safety lamp, 11serial communication, 47service, 32service outlet, 65space requirements, 7standards, 10stop point, 27structure, 7system builder, 18system signals, 41

T

testing, program, 28touch, 55touch screen, 15trap routines, 42troubleshooting, 32TrueMove, 34

U

UPS, 21, 24USB, 56USB, flash disk interface, 21

V

variants, 51volume, 7

W

windows, 15working space, restricting, 11

70 Rev.2 3HAC 021785-001

Index

3H
AC 021785-001 Rev.2 71

Index

72 Rev.2 3HAC 021785-001

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