Getting Started, Irc5 and Robotstudio: Operating Manual

ABB Robotics
Operating manual
Getting started, IRC5 and RobotStudio
Trace back information:
Workspace Main version a17 (not checked in)
Published 2012-09-06 at 10:21:34
Skribenta version 896
Operating manual
Getting started, IRC5 and RobotStudio
Document ID: 3HAC027097-001
Revision: J
© Copyright 2004-2012 ABB. All rights reserved.

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

ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
Table of contents
Table of contents
Overview ........................................................................................................................................... 7
Safety note ........................................................................................................................................ 9
1 Procedures 11
1.1 Procedure for single robot systems ...................................................................... 11
1.2 Procedure for MultiMove systems ........................................................................ 13
1.3 Common procedures for all systems ..................................................................... 16
2 General information 27
2.1 What you need to get the system started ............................................................... 27
2.2 What is a FlexPendant? ...................................................................................... 30
2.3 What is RobotStudio? ........................................................................................ 37
2.4 What is RobotWare? .......................................................................................... 38
2.5 About the media pool ........................................................................................ 39
2.6 When to use the FlexPendant and RobotStudio ...................................................... 40
2.7 Product documentation, M2004 ............................................................................ 42
Index 45
3HAC027097-001 Revision: J 5
This page is intentionally left blank
Overview
Overview
About this manual
This manual is to be used when starting up the system for the very first time. It
contains excerpts from other documents included in the robot system delivery.
Usage
This manual contains instructions for starting up the IRC5 robot controller for the
very first time after the physical installation has been completed.
Who should read this manual?

This manual is intended for:
• Commissioning personnel
Prerequisites
The reader should be familiar with:
• Mechanically installing the robot hardware.
• Be trained in robot operation.
The contents of the manual assumes all hardware (manipulator, controller and
such) has been installed correctly and connected to each other.
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
1Procedures Procedures for setup and startup of the IRC5 robot system.
2General Descriptions of the parts in IRC5 robot system.
References
Reference Document Id
Product manual - IRC5 3HAC021313-001
Operating manual - IRC5 with FlexPendant 3HAC16590-1
Operating manual - RobotStudio 3HAC032104-001
Operating manual - Trouble shooting IRC5 3HAC020738-001
Technical reference manual - System parameters 3HAC17076-1
Application manual - MultiMove 3HAC021272-001
Revisions
Revision Description
- Replaces manual with document id 3HAC 021564-001.
Released with RobotWare 5.08.
A Polish translation added.
B RobotStudio Online is integrated in RobotStudio. Title adjusted.
C Updated information on installing and licensing RobotStudio.
Continues on next page

Overview
Continued
Revision Description
D Updated the section Common procedures for all systems on page 16 with the
information on Installing RobotStudio.
E Released with RobotWare 5.13.
Updated information in the section Common procedures for all systems on
page 16
Added steps on downloading a system to a controller. See How to create a
system using RobotStudio on page 24.
F Released with RobotWare 5.13.02.
Updated information about the RobotWare key delivery. See How to create a
system using RobotStudio on page 24.
G Released with RobotWare 5.14.
• Added the procedure How to switch off power. See How to switch off
power on page 26.
• Removed references to RobotStudio trial period activation.
H Released with RobotWare 5.14.02
Added information on IRC5 Compact Controller and Panel Mounted Controller.
Updated the procedures How to switch on power on page 24 and How to switch
off power on page 26.
J Released with RobotWare 5.15
Updated and reworked the sections relating to RobotStudio installation, licens-
ing and activation, under Common procedures for all systems on page 16.
8 3HAC027097-001 Revision: J
Safety note
Safety note
Overview
Please note that there is no information regarding safety aspects in this manual!
In an effort to keep this manual short, there is no information regarding:
• safe handling and operation of the equipment
• generic reference information
• detailed procedures
This information can be found in the Product manuals or the Operating manuals
delivered with the robot system.
1 Procedures
1.1 Procedure for single robot systems
1 Procedures
Overview
This instruction is valid for IRC5 single robot systems.
A single robot system contains any of the following
• Single Cabinet Controller (controller with integrated Control Module and
Drive Module)
• Dual Controller (Control Module to which one Drive Module is connected)
• IRC5 Compact Controller
• Panel Mounted Controller
How to get started

This procedure details how to get started with a single robot system.
Action Info/illustration
1 Mechanically install the robot and controller, and These procedures are detailed in
connect the electrical power and signal cables the Product Manuals of robot and
between them. Also connect the electrical power controller respectively.
supply.
2 Make sure all safety related connections are made Refer to the work station wiring
correctly. diagram.
3 Connect the FlexPendant to the controller.
xx0500001854
A: FlexPendant connector, Single

Cabinet Controller
Note
The FlexPendant connector may

be placed in different positions on
different controllers, but they look
similar on all controllers.

1 Procedures
Continued
Action Info/illustration
4 If the robot system is delivered with fully functional
system software installed, you can proceed as de-
tailed in section How to switch on power in Common
procedures for all systems on page 16.
If no functional system software has been installed,
please proceed as detailed in section Common
1 Procedures
1.2 Procedure for MultiMove systems
Overview
This instruction is valid for IRC5 multi robot systems, that is, systems using the
MultiMove option.
xx0400001042
A MultiMove robot system contains either a Single Cabinet Controller (an integrated
Control Module and Drive Module as shown in the illustration above) or a separate
Control Module to which a number of Drive Modules (one for each robot being run
by the system) have been connected. Up to four robots may be operated by a
MultiMove system.
Note
IRC5 Compact Controller does not support MultiMove.
Note
All multi robot systems are configured as single robot systems on delivery. In
order to be fully functional as multi robot systems, these systems must be
re-configured.
How to perform this is detailed in Operating manual - RobotStudio.
How to get started

This procedure details how to get started with a multi robot system.
Action Info
1 Mechanically install the robot and control- These procedures are detailed in the
ler, and connect the electrical power and Product Manuals of robot and controller
signal cables between them. Also connect respectively.
the electrical power supply.

1 Procedures
Continued
Action Info
2 Connect the Ethernet cables from each
Drive Module to the Control Module Ether-
net card.
Make sure the Drive Modules are connec-
ted in the correct order! The order must
correspond to the order in which the key
strings are entered when creating the sys-
tem.
xx0400001141
Connections:
• A: Robot communication card
• B: Ethernet card
• C: Ethernet connection to Drive
Module #1 (connected on delivery)
• D: Ethernet connection to Drive
Module #2
• E: Ethernet connection to Drive
Module #3
• F: Ethernet connection to Drive
Module #4
3 Before connecting the safety signal cables,
remove jumpers from connectors X7, X8,
X14 and X17 as required by the number of
Drive Modules to connect.
Connect the safety signal cables from each
Drive Module to the Control Module panel
board as shown in the figure.
xx0400001295
Connections:
• X7: safety signal cable to Drive
Module #1(connected on delivery)
Module #2
Module #3
Module #4
4 Make sure all safety related connections Refer to the work station wiring diagram.
are made correctly.

1 Procedures
Continued
Action Info
5 Connect the FlexPendant to the controller.
xx0500001854
A: FlexPendant connector, Single Cabinet

Controller
6 Proceed as detailed in section Common
1 Procedures
1.3 Common procedures for all systems
Overview
These procedures are common for installing all robot systems.
Installation options and prerequisites
Note
You should have administrator privileges on the PC before installing RobotStudio.

RobotStudio is categorized into the following two feature levels:
• Basic - Offers selected RobotStudio functionality to configure, program, and
run a virtual controller. It also includes online features for programming,
configuring, and monitoring a real controller connected over Ethernet.
• Premium - Offers full RobotStudio functionality for offline programming and
simulation of multiple robots. The Premium level includes the features of the
Basic level and requires activation.
In addition to the Premium functionality, there are add-ins like PowerPacs and
options for CAD converters available.
• PowerPacs provides enhanced features for selected applications.
• Options for CAD converters allows import of different CAD formats.
RobotStudio offers the following installation options:
• Minimal - Installs only the features required to program, configure, and
monitor a real controller connected over Ethernet.
• Complete - Installs all the features required to run the complete RobotStudio.
If installed with this option, additional features of Basic and Premium
functionality are available.
• Custom - Installs user-customized features. This option allows excluding
unwanted robot libraries and CAD converters.
Note
RobotStudio 5.15 64-bit edition is installed for the Complete installation option
on computers that have a 64-bit operating system. The 64-bit edition allows larger
CAD-models to be imported as it can address more memory than the 32-bit
version. However, the 64-bit edition has the following limitations:
• PowerPacs, Visual Studio Tools for Applications, and any customized add-ins
that use PC-SDK are not supported
• ScreenMaker is not supported
• Jupiter import is not supported
• Import of stations and libraries from RobotStudio 4.0 (for S4) is not supported
• Add-ins will be loaded from the following folder
C:\Program Files (x86)\ABB Industrial IT\Robotics
IT\RobotStudio 5.15\Bin64\Addins

1 Procedures
Continued
How to install RobotStudio on a PC
Action
1 Insert the robot software DVD in the PC.
• If a menu for the DVD is opened automatically, continue with step 5.
• If no menu for the DVD is opened, continue with step 2.
2 On the Start menu, click Run.
3 In the Open box, type the drive letter for your DVD drive followed by:
:\launch.exe
If your DVD drive has the letter D, then type: D:\launch.exe
4 Click OK.
5 Select the language for the DVD menu.
6 On the DVD menu, click Install.
7 On the installation menu, click RobotStudio. This opens the installation wizard, which
guides you through the rest of the software installation.
8 After installing Robotstudio, you can proceed with installing RobotWare.
Go to the installation menu, and click RobotWare. This opens this installation wizard,
which guides you through the rest of the RobotWare installation.
9 This step is optional, and is for installing the Track mediapool.
On the Install products menu, click Additional Options. This opens a file browser
that displays the Track mediapool installation and other available options.
Double-click the TrackMotion folder and then the file setup.exe to start the installation
wizard and proceed.
After installing RobotStudio, proceed with activating your RobotStudio installation.
Knowing which RobotStudio version is installed

The version number of your RobotStudio installation is displayed on the RobotStudio
title bar.
Activation of RobotStudio license

Activation of your RobotStudio installation is a procedure for validating your
RobotStudio license. To continue using this with all of its features, you must activate
it. RobotStudio Product Activation is based on Microsoft anti-piracy technology
and is designed to verify that software products are legitimately licensed. Activation
works by verifying that the Activation Key is not in use on more personal computers
than are permitted by the software license.
When you start RobotStudio for the first time after installation, you are prompted
to enter your 25-digit Activation Key (xxxxx-xxxxx-xxxxx-xxxxx-xxxxx). The software
performs in the Basic Functionality mode if you do not use a valid Activation Key.
After the installation is activated, you will have valid licenses for the features
covered by your subscription.
Note
Activation is not required for Minimal installation, or for Basic Functionality mode
of the Complete or Custom installation.

1 Procedures
Continued
What is Basic Functionality mode

In Basic Functionality mode, which is a reduced functionality mode, RobotStudio
allows only the use of the basic features for the real and the virtual controller. No
existing files or stations are harmed in this mode. After activating your software,
you will have full functionality for the features you have purchased.
A real controller can be programmed, configured and monitored over Ethernet
without activating your installation of RobotStudio. Activation, however, will provide
access to the Premium productivity features that will make your engineering work
more efficient.
How to activate RobotStudio

Use the Activation Wizard to activate your RobotStudio installation. When you start
RobotStudio for the first time after installation, the wizard starts automatically and
prompts you for the Activation Key. If you do not want to activate your copy of
RobotStudio at installation, you can do so later using the Activation Wizard.
Note
If you have a problem with your activation, contact your local ABB customer
support representative at the e-mail address or telephone number provided at
www.abb.com/robotics.
For using the Activation Wizard, follow this procedure.
Action
1 On the File tab, click Options and go to General:Licensing.
2 On the Licensing page to the right, click Activation wizard to launch the Activation
Wizard.
3 In the Activation Wizard, on the Activate RobotStudio page, indicate whether you have
a Standalone License or a Network License, and then click Next.
If you have chosen Standalone License, you will proceed to the Activate a Standalone
License page. See Activate automatically over the Internet or manually on page 18
for further steps.
If you have chosen Network License, you will proceed to the Network License page.
See Network Licensing on page 19 for further steps.
Activate automatically over the Internet or manually

The Activation Wizard gives you two choices on how to proceed. You can choose
either automatic activation over the Internet or manual activation. These are
explained in the following section.
Automatic Activation (recommended)

In Automatic Activation, the Activation Wizard automatically contacts and sends
your activation request to the ABB licensing servers over your Internet connection.
Your license will then be automatically installed and your product will be ready for
use.
For Automatic Activation you need a working Internet connections and also a valid
Activation Key that has not exceeded the number of installations allowed.

1 Procedures
Continued
RobotStudio must be restarted after the activation has been successfully completed.
Note
If you choose to activate over the Internet but are not currently connected to the
Internet, then the wizard alerts you that there is no connection.
Manual Activation
1 If the computer does not have a working Internet connection, you must
proceed with Manual Activation:
2 Create a license file by selecting the option Step 1:Create a license request
file.
Proceed through the wizard, enter your Activation Key and save the License
Request File to your computer.
3 Use a removable storage medium, such as a USB stick or floppy disk, to
transfer the file to a computer with an Internet connection. In that computer,
open a web browser, go to http://www101.abb.com/manualactivation/ and
follow the instructions given.
The result will be a License File that should be saved and transferred back
to the computer having the installation awaiting activation.
4 Relaunch the Activation Wizard and go through the steps until you reach the
Activate a Standalone License page.
5 Under Manual Activation, select the option Step 3:Install a license file.
Proceed through the wizard, selecting the License File when requested. Upon
completion, RobotStudio is activated and ready for use.
RobotStudio must be restarted after the activation has been successfully completed.
Network Licensing
Network licensing allows you to centralize license management by installing licenses
on a single server rather than on each individual client machine. The server
administers the licenses to the clients as required. A single network license allows
several clients to use the software.
Network Licensing is set up in the following stages:
1 Install the server for network licensing (See Installing the Network Licensing
Server on page 20)
2 Activate the licenses for network licensing (See Using the SLP Server Web
Interface on page 20)
3 Set up the client for network licensing (See Setting up Network Licensing in
the client on page 21)
Tip
Network licenses are displayed as Network in the View Installed License Keys
link of the Licensing page.

1 Procedures
Continued
Installing the Network Licensing Server

Network licensing in RobotStudio uses the SLP Distributor server as the network
licensing server. It manages the allocation of network license keys to the clients.
You can install the SLP Distributor server from the Utilities\SLP Distributor directory
of the RobotStudio distribution.
Note
You require administrative privileges for installing and configuring the SLP
Distribution server.
The installer requires the following:
• Windows Server 2008, Windows 7, or Windows Vista.
• .NET Framework 3.5 SP1
The SLP Distributor server is installed as a service that starts automatically with
Windows. It requires two open TCP ports, by default 2468 (for the web interface)
and 8731 (for licensing). The installer opens these ports in the standard Windows
Firewall, but any third-party firewall must be configured manually by the system
administrator.
Using the SLP Server Web Interface

Once the SLP server is online, you can access its web interface on the address
http://<server>:2468/web.
The following table shows how to use the server's web interface.
To... Use...
Activate new network licenses The Activation tab. Submit the activation key provided
by ABB.
Note that the server must have a working internet con-
nection as manual activation is not supported. The
number of network licenses activated depends on the
activation key provided.
View the installed licenses The Home tab. Under Dashboard, click Details.
Alternatively, click the Products tab.
Both these open the Product details for RobotStudio
page, where details about the installed licenses are dis-
played.
View the usage of licenses The Home tab. Under Dashboard, click Usage.
Alternatively, click the Usage tab.
Both these open the Current usage of RobotStudio page,
which lists the following in a table:
• Licenses which are currently allocated
• Client to which each license is allocated to
• Number of remaining licenses available for use
Each table row corresponds to one client system.

1 Procedures
Continued
Note
Certain proxy issues upon activation in the SLP server's web interface may
produce a messages which only states Activation failed. Such a case may happen
when the system account that the SLP-Distributor-service is executed in, does
not have the rights to read the user profile. As a workaround, follow this
procedure:
1 Open the Services control panel (services.msc)
2 Open properties for InishTech SLP Distributor Service
3 Change Log on as to an actual named user, preferably the currently logged
on user
4 Restart the service and re-attempt an activation.
5 After your re-attempt, change Log on as back to Local System account and
restart the service.
Setting up Network Licensing in the client
Note
You require Administrative privileges to store this configuration.

You need to use the RobotStudio Activation Wizard in the client system for setting
up Network Licensing.
Use this procedure to set up Network Licensing for a client system.
Action
1 On the File tab, click Options and go to General:Licensing.
Wizard.
3 In the Activation Wizard, on the Activate RobotStudio page, choose the option I want to
specify a network license server and manage server license, and then click Next.
You will proceed to the License Server page.
4 Specify the name or IP address of the License Server, and then click Finish.
If Windows UAC is enabled, a confirmation dialog appears. This prompts you to restart
RobotStudio in order to start using the specified server.
To go to the SLP Distributor server web interface, click the Open the server dashboard
link. For information about using the server dashboard, see Using the SLP Server Web
Interface on page 20.
Note that the changes made are not applied until RobotStudio is restarted.
Note
For Network Licensing to work, the client system should be online with the server.
For information about enabling licensing while working offline, see Using
Commuter Licenses on page 22.

1 Procedures
Continued
Using Commuter Licenses

Commuter licenses allow a client system to work offline from the license server.
You can check out a license from the server for a specified number of days. During
this period the checked out license is unavailable to other users. The commuter
license is made available for other clients only when it is manually checked in back
to the server.
The commuter license in the client system expires when the check out time expires.
In this case, on starting RobotStudio in the client system, the Network License
dialog opens automatically and prompts you to check in the license back to the
server.
Note
It is not possible to check out specific features in the license. All features in a
license are included when it is checked out.
To check in/check out a commuter license, you need to use the Activation Wizard.
Use this procedure to check in/check out a commuter license.
Action
1 On the File menu, click Options and select General: Licensing
Wizard.
3 In the Activation Wizard, on the Activate RobotStudio page, choose I want to check out
or check in a commuter license and click Next.
You will proceed to the Commuter License page.
4 Under Commuter License, you will be presented one of the following options as per your
requirement:
• Check out a commuter license key - In the Check out days box specify the
specify the number of days for which you wish to keep the license.
This option is disabled if you already have a commuter license checked out.
• Check in a commuter license key - Choose this option to return the currently
checked out license to the server.
This option is enabled only if a commuter license is already checked out. If so,
the expiration date and time of the license is also displayed.
5 Click Finish to complete the check in/check out.
Tip
Network licenses checked-out as commuter licenses are displayed as Floating

(checked out) in the View Installed License Keys link of the Licensing page.
Knowing whether your RobotStudio installation is activated
Action
1 On the File tab, click Options and then go to General:Licensing.
2 On the Licensing page to the right, select View Installed License Keys to see the
status of your current license.
The Licenses opens, where you can view all the valid licenses for the features covered
by your subscription.

1 Procedures
Continued
How to configure and connect a PC or network to the controller

The illustration below shows the two main ports on the controller Computer Unit:
the Service Port and the LAN port. Make sure the LAN (factory network) is not
connected to any of the service ports!
xx0600002889
Note
Service port and LAN port are positioned differently in IRC5 Compact Controller
and Panel Mounted Controller.
A Service port
B LAN port (connects to factory LAN)
Action Illustration
1 Make sure the network setting on the PC Refer to the system documentation for your
to be connected is correct. PC, depending on the operative system
you are running.
The PC must be set to “Obtain an IP ad-
dress automatically” or set as described
in Service PC Information in the Boot Ap-
plication.
2 Use the delivered category 5 Ethernet The cable is delivered in the RobotWare
crossover boot cable with RJ45 connect- product box.
ors.
3 Connect the boot cable to the network port
of your PC.
xx040000
• A: network port
The placement of the network port may
vary depending on the PC model.

1 Procedures
Continued
Action Illustration
4 Connect the boot cable to the service port.
How to create a system using RobotStudio

Normally, no system will have to be created for single robot systems since one is
already installed on delivery. However, if your system uses the option MultiMove,
you must create a new system defining all robots in the system.
If for some reason the delivered system does not work, a new system must be
created and loaded as outlined below.
A detailed procedure is given in Operating manual - RobotStudio. For MultiMove
systems, more information is also described in Application manual - MultiMove.
Action Info
1 Start RobotStudio and click System Builder.
2 Before creating a new system, make sure the follow- The RobotWare key is a license
ing criteria are met: key that determines which robot
• The RobotWare media pool must be installed model(s) to use and which Robot-
on your PC. Ware options to run on the control-
• You must have a RobotWare key for the ler. It is printed on a sheet of pa-
system, if the system is to run on a controller. per delivered with the controller
cabinet.
3 Click Create New.
A wizard for creating new systems is started.
4 Follow the steps in the wizard: Some of the steps are optional
• Enter name and location and can be skipped.
• Enter RobotWare key(s)
• Add additional options
• Modify options
• Add configuration files
• Add files to home directory
• View summary
• Finish
5 In the System Builder dialog box, select the system
from the list and then click Download to Controller
to bring up a dialog box.
6 In the dialog box, connect to the controller.
7 Click Load to load the new system to the controller.
8 Answer Yes to the question Do you want to load
the system.
How to switch on power

The mains power switch is located on the front of the controller/module.
• For a Panel Mounted Controller, the placing of the switch can vary.
• For a Dual Controller, there is one switch per module.

1 Procedures
Continued
The following illustration shows the switch in power on state.
en0400000793
Note
The power switch can look different on a Panel Mounted Controller.

Action Info
1 For a Dual Controller, switch on the power to each For all other controllers, proceed
Drive Module. to step 2.
2 Switch on the power to the Control Module. The system will now start up,
which will take a couple of
minutes. The system will be ready
to operate when the FlexPendant
displays the start window.
If the system does not start up, or
if the start window is not dis-
played, please proceed as de-
tailed in Operating manu-
al - Trouble shooting IRC5.
3 After switching the power on, proceed with loading See How to load calibration data
calibration data. on page 25.
How to load calibration data

The calibration data is normally stored on the serial measurement board of each
robot, regardless of whether the robot runs an absolute measurement system
(Absolute Accuracy option is installed, AbsAcc) or not. This data is normally
transferred automatically to the controller when the system is powered up, and in
such cases no action is required by the operator.
Verify that the correct SMB data has been loaded into the system as detailed below.
In a MultiMove system, this procedure must be repeated for each robot.
Action
1 On the FlexPendant, tap the ABB menu, then tap Calibration and select a mechanical
unit.
2 Tap SMB memory and then tap Show status.
The data is displayed with status on the SMB and on the controller.

1 Procedures
Continued
Action
3 If Valid is displayed under the headings Cabinet Memory and SMB memory, calibration
data is correct.
If not, the data (on the SMB board or in the controller) must be replaced with the correct
one as detailed below:
• If, for instance, the SMB board has been replaced, transfer data from controller
to SMB board.If the controller has been replaced, transfer data from the SMB
board to the controller.
• Transfer data by tapping SMB Memory, Update, and then selecting which data
to update.
4 After loading calibration data, proceed with updating the revolution counters. See How
to update revolution counters on page 26.
How to update revolution counters

In a MultiMove system, this procedure must be repeated for each robot.
Action Info
1 Manually run the robot, using the joystick on the The calibration position of each
FlexPendant, to a position close to the calibration axis is indicated by the calibration
position. marks.
2 After positioning all axes within the scale indicated Caution!
by the calibration marks, store the revolution If a revolution counter is incor-
counter settings. rectly updated, it will cause incor-
On the FlexPendant, tap the ABB menu, then tap rect robot positioning, which in
Calibration. Select the mechanical unit to be calib- turn may cause damage or injury!
rated. Tap Update revolution counters and follow Check the calibration position
the instructions provided. very carefully after each update.
How to switch off power

The mains power switch is located on the front of the controller/module.
• For a Panel Mounted Controller, the placing of the switch can vary.
• For a Dual Controller, there is one switch per module.
The following illustration shows the switch in power off state.
en1000001317
Action Info
1 For a Dual Controller, switch off the power to each For all other controllers, proceed
Drive Module to step 2.
2 Switch off the power to the Control Module. The system will now shut down,
which will take a couple of
minutes.
2 General information
2.1 What you need to get the system started
Illustration
The illustration depicts, in a schematic way, the delivered parts, the software tools
to install them and the basic work flow.
en0400000766
Parts
Description Described in
A Manipulator (a generic model shown) Documents specified in sec-
tion Product documentation,
M2004 on page 42.
B1 Control Module, IRC5, containing the control electron- Documents specified in sec-
ics of the robot system. tion Product documentation,
M2004 on page 42.

Continued
B2 Drive Module, IRC5, containing the power electronics Documents specified in sec-
of the robot system. tion Product documentation,
In a Single Cabinet Controller the Drive Module is in- M2004 on page 42.
cluded in the single cabinet.
In a MultiMove system, there is more than one Drive
Module.
C RobotWare DVD containing all robot software spe-
cified in section What is RobotWare? on page 38, and
RobotStudio installation package.
D Documentation DVD. Containing documentation
files as specified in section
Product documentation,
M2004 on page 42.
E Robot system software being run by the robot control- Documents specified in sec-
ler. The system has been loaded into the controller tion Product documentation,
from the server on the local area network. M2004 on page 42.
F RobotStudio PC software installed on PC x. RobotStu- Documents specified in sec-
dio is used for loading the RobotWare software to the tion Product documentation,
server as well as configuring the robot system and M2004 on page 42, and in
then loading the complete robot system into the robot section What is RobotStudio?
controller. on page 37.
RobotStudio is used to perform tasks as defined in
section When to use the FlexPendant and RobotStu-
dio on page 40.
G Calibration data diskette for systems running theAb-
solute Accuracyoption only. Calibration data for sys-
tems without this option is normally delivered on the
Serial Measurement Board (SMB).
H FlexPendant, which is connected to the controller, is Documents specified in sec-
used to perform tasks as defined in section When to tion Product documentation,
use the FlexPendant and RobotStudio on page 40. M2004 on page 42.
J Server on network (not included in the delivery). This
may be used for manually storing:
• RobotWare
• Complete robot systems
• Documentation files
In this context, the server may be considered as a
storage unit used by the PC x, and may even be the
same unit!
The server may be disconnected when not transfer-
ring data between the server and controller!
PC K The server may be used for:
• All RobotWare software may be manually
stored using the PC and RobotStudio.
• Complete configured system files may be
manually stored after being created using the
portable PC.
• All robot documentation files may be manually
stored after being installed using the portable
PC and RobotStudio.
In this context, the server may be considered as a
storage unit used by the portable PC.

Continued
M RobotWare license key. The original key string is
printed on a paper (for the Dual Controller there is
one key for the Control Module and one for the Drive
Module, and in a MultiMove system there is one key
for each module) delivered inside the Drive Module.
If ordered, the RobotWare license key is installed on
delivery, so no further actions are required to get the
system running.
N Serial Measurement Board (SMB) handling resolver
data and storing calibration data. For systems not
running theAbsolute Accuracyoption, the calibration
data is stored on the SMB on delivery.
PC x PC (not included in the delivery), may even be the
same unit as the server J, shown above!
The PC may be disconnected when not transferring
data between the server and controller!
2.2 What is a FlexPendant?
Introduction to the FlexPendant

The FlexPendant (occasionally called TPU or teach pendant unit) is a hand held
operator unit used to perform many of the tasks involved when operating a robot
system: running programs, jogging the manipulator, modifying robot programs
and so on.
The FlexPendant is designed for continuous operation in harsh industrial
environment. Its touch screen is easy to clean and resistant to water, oil and
accidental welding splashes.
Complete computer and integral part of IRC5

The FlexPendant consists of both hardware and software and is a complete
computer in itself. It is an integral part of IRC5, connected to the controller by an
integrated cable and connector. The hot plug button option, however, makes it
possible to disconnect the FlexPendant in automatic mode and continue running
without it.

Continued
Main parts
These are the main parts of the FlexPendant.
xx0900000022
A Connector
B Touch screen
C Emergency stop button
D Joystick
E USB port
F Enabling device
G Stylus pen
H Reset button
Joystick
Use the joystick to move the manipulator. This is called jogging the robot. There
are several settings for how the joystick will move the manipulator.
USB port
Connect a USB memory to the USB port to read or save files. The USB memory
is displayed as drive /USB:Removable in dialogs and FlexPendant Explorer.
Note! Close the protective cap on the USB port when not used.

Continued
Stylus pen
The stylus pen included with the FlexPendant is located on the back. Pull the small
handle to release the pen.
Use the stylus pen to tap on the touch screen when using the FlexPendant. Do not
use screw drivers or other sharp objects.
Reset button
The reset button resets the FlexPendant, not the system on the controller.
Note
The USB port and the reset button work on systems using RobotWare 5.12 or
later. These will not work on older systems.
Hard buttons
There are dedicated hardware buttons on the FlexPendant. You can assign your
own functions to four of the buttons.
xx0900000023
A-D Programmable keys, 1 - 4. How to define their respective function is detailed in

section Programmable keys, in Operating manual - IRC5 with FlexPendant.
E Select mechanical unit.
F Toggle motion mode, reorient or linear.
G Toggle motion mode, axis 1-3 or axis 4-6.
H Toggle increments.
J Step BACKWARD button. Executes one instruction backward as button is
pressed.
K START button. Starts program execution.
L Step FORWARD button. Executes one instruction forward as button is pressed.
M STOP button. Stops program execution.
Note
The select and toggle buttons work on systems using RobotWare 5.12 or later.
These will not work on older systems.

Continued
How to hold the FlexPendant

The FlexPendant is typically operated while being held in the hand. A right-handed
person uses his left hand to support the device while the other hand performs
operations on the touch screen. A left-hander, however, can easily rotate the display
through 180 degrees and use his right hand to support the device. For more
information about adapting the FlexPendant to left-handness, see .Operating
manual - IRC5 with FlexPendant.
en0400000913

Continued
Touch screen elements

The illustration shows important elements of the FlexPendant touch screen.
en0300000588
A ABB menu
B Operator window
C Status bar
D Close button
E Task bar
F Quickset menu
ABB menu
The following items can be selected from the ABB menu:
• HotEdit
• Inputs and Outputs
• Jogging
• Production Window
• Program Editor
• Program Data
• Backup and Restore
• Calibration
• Control Panel
• Event Log
• FlexPendant Explorer

Continued
• System Info
• etc.
This is further described in section The ABB Menu in Operating manual - IRC5
with FlexPendant.
Operator window
The operator window displays messages from robot programs. This usually happens
when the program needs some kind of operator response in order to continue.
This is described in section Operator window in Operating manual - IRC5 with
FlexPendant.
Status bar
The status bar displays important information about system status, such as
operating mode, motors on/off, program state and so on. This is described in
section Status bar in Operating manual - IRC5 with FlexPendant.
Close button
Tapping the close button closes the presently active view or application.
Task bar
You can open several views from the ABB menu, but only work with one at a time.
The task bar displays all open views and is used to switch between these.
Quickset menu
The quickset menu provides settings for jogging and program execution. This is
described in section The Quickset menu in Operating manual - IRC5 with
FlexPendant.
Handling and cleaning

• Handle with care. Do not drop, throw, or give the FlexPendant strong shock.
It can cause breakage or failure.
• When not using the device, hang it on the wall bracket provided for storage
so it does not accidentally fall.
• Always use and store the FlexPendant in such a way that the cable does not
become a tripping hazard.
• Never use sharp objects (such as screwdriver or pen) for operating the touch
screen. This could damage the touch screen. Instead use your finger or a
stylus (located on the back on FlexPendant with USB port).
• Clean the touch screen regularly. Dust and small particles can clog the touch
screen and cause it to malfunction.
• Never clean the FlexPendant with solvents, scouring agent, or scrubbing
sponges. Use a soft cloth and a bit of water or mild cleaning agent. See
Product manual - IRC5, section Cleaning the FlexPendant.
• Always close the protective cap on the USB port when no USB device is
connected. The port can break or malfunction if exposed to dirt or dust.

Continued
CAUTION
A disconnected FlexPendant should be stored in such a way that it cannot be

mistaken for being connected to the controller.
Operated in fifteen languages

As suggested by its name, the FlexPendant is designed with flexibility and
adaptation to end-users’ specific needs in mind. Currently, it can be operated in
15 different languages, including Asian character-based languages such as Chinese
and Japanese.
The individual FlexPendant supports up to three languages, selected before the
installation of the system to the robot controller. Switching from one of the installed
languages to another is easy. For more information about changing language, see
Operating manual - IRC5 with FlexPendant.
2.3 What is RobotStudio?
2.3 What is RobotStudio?
Overview
RobotStudio is a computer application for the offline creation, programming, and
simulation of robot cells.
RobotStudio is available in complete, customized, and minimal installation. The
minimal installation is used for working in online mode on the controller, as a
complement to the FlexPendant. The Complete (and customized) installation offers
advanced programming and simulation tools.
RobotStudio for real controllers

RobotStudio allows the following operations when connected to a real controller:
1 Creating, installing, and maintaining systems, using the System Builder.
2 Text-based programing and editing, using the RAPID Editor.
3 File manager for the controller.
4 Administrating the User Authorization System.
2.4 What is RobotWare?
2.4 What is RobotWare?
Concept
RobotWare is a generic term for all software to be installed in the robot system
designed to operate the robot.
RobotWare is installed and stored in the media pool (Mediapool) folder on a
PC/server. The media pool is described in section About the media pool on page 39.
RobotWare is delivered on a DVD and this contains software for all available models,
options and such.
However, the RobotWare license keys, required to access the software, are
delivered as character strings printed on a piece of paper delivered with the
controller cabinet. There is one key for the Control Module, and one key for each
Drive Module.
When adding functionality at a later date, a new controller license key is required
to access the functions. The key is available from your local ABB representative.
2.5 About the media pool
2.5 About the media pool
Overview
The media pool is a folder on your PC that contains the RobotWare software. It is
from the media pool that you select programs and options when building systems.
The default media pool

If RobotWare is installed with default settings on the PC, the default media pool is
located in the folder C:\Program Files\ABB Industrial IT\Robotics IT\Mediapool
Customized media pools

You can create customized media pools by creating new folders to which you copy
RobotWare files from existing media pools. You can also update or modify a media
pool by importing new parts of RobotWare using the Import Option tool in
RobotStudio.
In RobotStudio, you then choose which media pool to use when creating new
systems.
Related information
See About the media pool on page 39for information about installing the default
media pool.
2.6 When to use the FlexPendant and RobotStudio
Overview
For operating and managing the robot, you either use the FlexPendant or
RobotStudio. The FlexPendant is optimized for handling robot motions and ordinary
operation, and RobotStudio is optimized for configuration, programming and other
tasks not related to the daily operation.
Start, restart and shut down the controller
To... Use...
Start the controller. The power switch on the controller's front panel.
Restart the controller. The FlexPendant, RobotStudio or the power switch on the
controller's front panel.
Shut down the controller. The power switch on the controller's front panel or the
FlexPendant, tap Restart, then Advanced.
Run and control robot programs
To... Use...
Jog a robot. The FlexPendant
Start or stop a robot program. The FlexPendant or RobotStudio
Start and stop background RobotStudio
tasks
Communicate with the controller
To... Use...
Acknowledge events. The FlexPendant.
View and save the controller's event logs. RobotStudio or the FlexPendant.
Back up the controller's software to files on RobotStudio or the FlexPendant.
the PC or a server.
Back up the controller's software to files on The FlexPendant.
the controller
Transfer files between the controller and net- RobotStudio or the FlexPendant.
work drives.
Program a robot
To... Use...
Create or edit robot programs RobotStudio to create the program's structure and most of
in a flexible way. This is suit- the source code and the FlexPendant to store robot posi-
able for complex programs tions and make final adjustments to the program.
with a lot of logic, I/O signals When programming, RobotStudio provides the following
or action instructions. advantages:
• A text editor optimized for RAPID code, with auto-text
and tool-tip information about instructions and para-
meters.
• Program check with program error marking.
• Close access to configuration and I/O editing.

Continued
To... Use...
Create or edit a robot program The FlexPendant.
in a supportive way. This is When programming, the FlexPendant provides the following
suitable for programs that advantages:
mostly consist of move instruc- • Instruction pick lists
tions.
• Program check and debug while writing
• Possibility to create robot positions while program-
ming
Add or edit robot positions. The FlexPendant.
Modify robot positions. The FlexPendant.
Configure the robot's system parameters
To... Use...
Edit the system parameters of the running RobotStudio or the FlexPendant
system.
Save the robot's system parameters as config- RobotStudio or the FlexPendant
uration files.
Load system parameters from configuration RobotStudio or the FlexPendant
files to the running system.
Load calibration data. RobotStudio or the FlexPendant
Create, modify and install systems
To... Use...
Create or modify a system. RobotStudio together with RobotWare and a valid
RobotWare Key.
Install a system on a controller. RobotStudio
Install a system on a controller from The FlexPendant.
a USB memory.
Calibration
To... Use...
Calibrate base frame etc. The FlexPendant
Calibrate tools, work objects etc. The FlexPendant
Related information
The table below specifies which manuals to read, when performing the various
tasks referred to:
Recommended use... for details, see manual... Document number
FlexPendant Operating manual - IRC5 with Flex- 3HAC16590-1
Pendant
RobotStudio Operating manual - RobotStudio 3HAC032104-001
2.7 Product documentation, M2004
Categories for manipulator documentation

The manipulator documentation is divided into a number of categories. This listing
is based on the type of information in the documents, regardless of whether the
products are standard or optional.
All documents listed can be ordered from ABB on a DVD. The documents listed
are valid for M2004 manipulator systems.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware will be
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools ).
• Spare parts list with exploded views (or references to separate spare parts
lists).
• Circuit diagrams (or references to circuit diagrams).
Technical reference manuals

The technical reference manuals describe reference information for robotics
products.
• Technical reference manual - Lubrication in gearboxes: Description of types
and volumes of lubrication for the manipulator gearboxes.
• Technical reference manual - RAPID overview: An overview of the RAPID
programming language.
• Technical reference manual - RAPID Instructions, Functions and Data types:
Description and syntax for all RAPID instructions, functions, and data types.
• Technical reference manual - RAPID kernel: A formal description of the
RAPID programming language.
• Technical reference manual - System parameters: Description of system
parameters and configuration workflows.

Continued
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, DVD with PC software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and trouble shooters.
The group of manuals includes (among others):
• Operating manual - Emergency safety information
• Operating manual - General safety information
• Operating manual - Getting started, IRC5 and RobotStudio
• Operating manual - Introduction to RAPID
• Operating manual - IRC5 with FlexPendant
• Operating manual - RobotStudio
• Operating manual - Trouble shooting IRC5, for the controller and manipulator.
Index
Index
A MultiMove system, 26
ABB menu, 34
Activate RobotStudio O
Automatic activation, 18 operator unit, 30
Manual activation, 19 operator window, 34
B P
backward button, 32 program a robot, 40
program execution start button, 32
C
calibration, 41 Q
calibration data, 25 quickset menu, 34
cleaning FlexPendant, 35
close button, 34 R
connector, 31 reset button
controller license key, 38 location, 31
control tools, overview, 40 using, 32
RobotStudio
E overview, 37
emergency stop button RobotWare
FlexPendant, 31 overview, 38
enabling device, 31 RobotWare, about the media pool, 39
Ethernet, 23 run button, 32
F S
FlexPendant start button, 32
cleaning, 35 status bar, 34
hardware buttons, 32 step
how to hold, 33 backward, 32
left-hander, 33 forward, 32
main parts, 31 stop button, 32
overview, 30 stylus pen
screen, 34 location, 31
forward button, 32 using, 32
system parameters, 41
H
Hard buttons, 32 T
hold-to-run button, 31 task bar, 34
teach pendant unit, 30
J toggle buttons, 32
joystick, 31 tool, overview control tools, 40
using, 31 touch screen, 30, 34
TPU, 30
L
LAN port, 23 U
USB port
M FlexPendant, 31
Media Pool, about, 39
Contact us
ABB AB
3HAC027097-001, Rev J, en
Discrete Automation and Motion
Robotics
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400
ABB AS, Robotics

Discrete Automation and Motion
Box 265
N-4349 BRYNE, Norway
Telephone: +47 51489000
ABB Engineering (Shanghai) Ltd.

5 Lane 369, ChuangYe Road
KangQiao Town, PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
www.abb.com/robotics

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ABB Robotics

© Copyright 2004-2012 ABB. All rights reserved.

© Copyright 2004-2012 ABB. All rights reserved.

Who should read this manual?

Continues on next page

How to get started

A: FlexPendant connector, Single

The FlexPendant connector may

Continues on next page

1.2 Procedure for MultiMove systems

IRC5 Compact Controller does not support MultiMove.

How to get started

Continues on next page

Continues on next page

A: FlexPendant connector, Single Cabinet

1.3 Common procedures for all systems

Installation options and prerequisites

You should have administrator privileges on the PC before installing RobotStudio.

Continues on next page

How to install RobotStudio on a PC

After installing RobotStudio, proceed with activating your RobotStudio installation.

Knowing which RobotStudio version is installed

Activation of RobotStudio license

Continues on next page

What is Basic Functionality mode

How to activate RobotStudio

Activate automatically over the Internet or manually

Automatic Activation (recommended)

Continues on next page

Continues on next page

Installing the Network Licensing Server

Using the SLP Server Web Interface

Continues on next page

Setting up Network Licensing in the client

You require Administrative privileges to store this configuration.

Continues on next page

Using Commuter Licenses

Network licenses checked-out as commuter licenses are displayed as Floating

Knowing whether your RobotStudio installation is activated

Continues on next page

How to configure and connect a PC or network to the controller

Continues on next page

How to create a system using RobotStudio

How to switch on power

Continues on next page

The following illustration shows the switch in power on state.

The power switch can look different on a Panel Mounted Controller.

How to load calibration data

Continues on next page

How to update revolution counters

How to switch off power

Continues on next page

Continues on next page

2.2 What is a FlexPendant?

Introduction to the FlexPendant

Complete computer and integral part of IRC5

Continues on next page

Continues on next page

A-D Programmable keys, 1 - 4. How to define their respective function is detailed in

Continues on next page

How to hold the FlexPendant

Continues on next page

Touch screen elements