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Product specification

Controller
IRC5 with FlexPendant RobotWare 5.06

Product Specification
Controller
IRC5 with FlexPendant RobotWare 5.06 3HAC 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, 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, and contents thereof must not be imparted to a third party nor be used for any unauthorized 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 AB Robotics SE-721 68 Vsters Sweden

Table of Contents
1 Description 7

1.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

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

1.2.1 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.3.1 Operators panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12


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

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

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

1.3.4 RobotStudio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Simulation and offline progamming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1.4 MultiMove (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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

1.5 Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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

1.6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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

1.7 Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3HAC 021785-001 Rev.2 26 26 26 26 27 27 3

Table of Contents
Program management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Editing programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Testing programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 1.8 Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Special routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Absolute measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 1.9 The RAPID Language and Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 1.10 Exception handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 1.11 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 User program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1.12 Robot Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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

1.13 Additional Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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

1.14 I/O System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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

1.15 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

1.15.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Ethernet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Serial channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3HAC 021785-001

Rev.2

Table of Contents
2 Specification of Variants and Options 51

2.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 2.2 Basic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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

2.3 Control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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

2.4 Drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC - link IRB 140, IRB 1400, IRB 2400, IRB 340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive unit capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional motors measurement board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive module cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Duty time counter (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 66 66 66 66 67 67 67 67

3HAC 021785-001

Rev.2

Table of Contents

3HAC 021785-001

Rev.2

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, operators panel, the mains switch, communication interfaces, Flex Pendant connection, service ports and some space for customer 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 programming. Furthermore, the Control Module offers 4 PCI slots for expansion boards in the computer.

Flexible Controller

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

Weight
max 250 kg 105 kg 110-145 kg

Data
Flexible Controller

Volume
1250 x 700 x 700 mm

Airborne noise level

Airborne noise level


Sound pressure level outside

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

3HAC 021785-001

Rev.2

1 Description
1.1.1 Introduction

C A E D B

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

Pos
A B C D E F

Name
Control Module Drive Module Operators panel Protection hood Controller color, rear part feet Controller color, front part, door and protection hood

Description

All cable connections at the front, optional covered NCS 7502 B (dark grey) NCS 2502 B (light grey)

Rev.2

3HAC 021785-001

1 Description
1.1.1 Introduction

A
705*

A
652 45

625

1250 722 708

1232

170

A- A
657

562
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.

3HAC 021785-001

Rev.2

429 4x14

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:
Standard
EN ISO 12100 -1 EN ISO 12100 -2 EN 954-1 EN 60204 EN 775 EN 61000-6-4 (option) EN 61000-6-2

Description
Safety of machinery, terminology Safety of machinery, technical specifications Safety of machinery, safety related parts of control systems Electrical equipment of industrial machines Electrical equipment of industrial machines EMC, Generic emission EMC, Generic immunity

Standard
IEC 204-1 IEC 529

Description
Electrical equipment of industrial machines Degrees of protection provided by enclosures

Standard
ISO 10218 ISO 9787

Description
Manipulating industrial robots, safety Manipulating industrial robots, coordinate systems and motions

Standard
ANSI/RIA 15.06/1999 ANSI/UL 1740-1998 (option) CAN/CSA Z 434-03 (option)

Description
Safety Requirements for Industrial Robots and Robot Systems. Safety Standard for Robots and Robotic Equipment Industrial Robots and Robot Systems - General Safety Requirements

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.
Safety function
Safety category 3

Description
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 executing 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 The robot can be operated either manually or automatically. In manmode 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

Safety function
Reduced speed

Description
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 The enabling device on the FlexPendant must be used to move the device 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 system, for two operator safety. Safe manual movement Over-speed protection Emergency stop The robot is moved using a joystick instead of the operator having to look at the FlexPendant to find the right key. The speed of the robot is monitored by two independent computers. There is one emergency stop push button on the controller and another one on the FlexPendant. Additional emergency stop buttons can be connected to the robots safety chain circuit. 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 robots safety functions to be activated both by peripheral equipment and by the robot itself.

Protective stop

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 programmed 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 Software space The movement of each axes can be restricted Hardware Limit switches can be connected to the robots 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. The control system complies with ULs (Underwriters Laboratory) requirements for fire safety. 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. 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 mechanical unit at a time can be jogged, selected from the FlexPendant.

Fire safety Safety lamp

MultiMove

3HAC 021785-001

Rev.2

11

1 Description
1.3.1 Operators panel

1.3 Operation
1.3.1 Operators panel

Control Module

D E

Figure 3 Control Module.

Pos
A B C D E F

Name
Mains switch and remote control of power to Drive Module(s) Emergency stop If pressed in, pull to release MOTORS ON Operating mode selector Safety chain LEDs (option) Service hatch -Ethernet connection -USB connection (option)

12

Rev.2

3HAC 021785-001

1 Description
1.3.1 Operators panel

Motors on MOTORS ON
Continuous light Fast flashing light (4Hz)

Operation
Ready for program execution.

Note

The robot is not calibrated or the The motors have been revolution counters are not switched on. updated. One of the protective space stops is active. The motors have been switched off.

Slow flashing light (1 Hz)

Operating mode selector

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

Description
Running production

Signs

Manual mode at reduced speed Programming and setup Max. speed 250 mm/s (600 inches/min.) Manual mode at full speed Testing at full program speed Equipped with this mode, the robot is not approved according to ANSI/UL
100%

Remote Control

Both the operators panel and the FlexPendant can be mounted externally, i.e. separated 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 customers panel, using serial communication or digital system signals.
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
1.3.1 Operators panel

Drive Module

C
Figure 4 Drive Module.

Pos
A B C

Description
Mains isolator switch. Stand by lamp indicates that electronic supply is switched on by the Control Module mains switch. Duty Time Counter (option) accumulates the hours (up to 99999.99 h) when the motors are in operation.

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 operators panel (see Figure 5) and RobotStudioOnline.
A B C

F E D

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.

Pos
A B C D E F

Description
Display User defined keys Emergency stop button Joystick Hold-to-run button (at the rear) Program execution keys

Information is presented on the display in an intuitive way. No previous programming 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.
Feature
Display

Description
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.

3HAC 021785-001

Rev.2

15

1 Description
1.3.2 FlexPendant

Feature
Program execution keys User-defined keys Hold-to-run Enabling device

Description
Keys for program start/stop and stepwise execution forward/backward. 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. A button which must be pressed continuously when running the program in manual mode with full speed. 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. The 3D joystick is used to jog (move) the robot manually; e.g. when programming the robot. The user determines the speed of this movement, large deflections of the joystick will move the robot quickly, smaller deflections will move it more slowly. The robot stops immediately when the button is pressed in.

Joystick

Emergency stop button

Example of FlexPendant window

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

16

Rev.2

3HAC 021785-001

1 Description
1.3.3 RobotStudioOnline

1.3.3 RobotStudioOnline
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 management, 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 control 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

Overview

3HAC 021785-001

Rev.2

17

1 Description
1.3.3 RobotStudioOnline

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 controllers 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

ABBs simultation and offline programming software RobotStudio allows robot programming 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 number 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.
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.

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 (typically 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).

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.

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, 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.

20

Rev.2

3HAC 021785-001

1 Description
1.5.1 Introduction

1.5 Memory
1.5.1 Introduction

Available memory

The controller has the following memory types:


Memory types
Fixed DRAM memory Flash disk memory

Size
64 MB or 256 MB 256 MB
1

Description
Working memory Mass memory Mass memory Removable mass memory

Hard disk, optionally instead of 20 GB the flash disk USB flash disk interface Customer selected

1. 256 MB in MultiMove robots.

DRAM memory

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


Areas
System software System software execution data User RAPID programs 6-17 MB (when installing different options, the user program memory will decrease, at most by about 1.0 MB).

Size

Mass memory

The mass memory is divided into four main areas.


Areas
Base area Release area System specific data area User mass memory area

Size
64 MB 40 MB 40 MB 20 MB

Description
Fail Safe partition for troubleshooting Permanent code for booting All the code for a specific release is stored All the run time specific data including the user program for a system is stored at backup Can be used for storing RAPID programs, data, logs etc.

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.

3HAC 021785-001

Rev.2

21

1 Description
1.5.1 Introduction

FlexPendant

DRAM memory 64 MB

Mass memory 256 MB/ 20 GB

System software Fail Safe 64 MB Data Boot 40 MB User RAPID program 6 or 17 * MB Power on - restore Release storage 40 MB
System data/user program 20 MB

Power off - store

Mass memory area available for the user 92 or > 19800 MB

Figure 7 Available memory.

Pos
*

Description
17 MB in MultMove robots.

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.
Instruction
MoveL or MoveJ

Robtarget marked (*)


312 bytes

Robtarget named
552 bytes

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1.6.1 Introduction

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 installation time, in order to take the additional robots into account.

Operating requirements

Requirements

Description

Dust and water protection accord- Controller electronics IP54 ing to IEC 529 Cooling 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- Control Module: +5oC (+41oF) to +45oC (+113oF) ation Control Module with option 708-2: +52oC (+125oF) Drive Module: +5oC (+41oF) to +52oC (+125oF) Note: for 66/7600 S5C as standard with option 708-2 +52C Ambient temperature during trans- -25oC (-13oF) to +55oC (+131oF) portation and storage for short periods (not exceeding 24 hours): up to +70oC (+158oF). Relative humidity Vibration during transportation and operation Bumps during transportation and operation Max. 95% at constant temperature 10-55 Hz: Max. 0.15 mm 55-150 Hz: Max. 20 m/s2 Max. 100 m/s2 (4-7 ms)

Power supply Mains voltage


Drive Module Control Module Mains voltage tolerance Mains frequency

Values
200-600 V, 3 phase 230 V, 1 phase, supplied from the Drive Module +10%, -15% 48.5 to 61.8 Hz

Controller rated power

Drive Module and Control Module together:


Robot Rated power

IRB 140, 1400, 2400, 4400, 6 kVA (transformer size) 340

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Robot
IRB 6600, 7600 Additional Drive Module

Rated power
13 kVA (transformer size) 6 or 13 kVA (transformer size)

Line fusing

Recommended line fusing:


Robot Voltage Description
3x16A slow-blowing 3x25A slow-blowing 3x25A slow-blowing 3x25A slow-blowing

IRB 140, 1400, 2400, 4400, at 400-600V 340 IRB 140, 1400, 2400, 4400, at 200-220V 340 IRB 6600, 7600 IRB 6600, 7600 at 400-600V at 200-220V

Power consumption

See Product specification for respective IRB.

UPS Computer system Value backup capacity (UPS)


At power interrupt 20 sec (maintenance free energy bank)

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:
Configuration
Authorization

Description
Password protection IRC5 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. User-defined lists of I/O signals. User-defined set of instructions. User-defined instructions. Customised operator dialogs. All text on the FlexPendant can be displayed in several languages. Calendar support. Action taken when the power is switched on. Action taken at an emergency stop. Action taken when the program is starting from the beginning. Action taken at program start. Action taken at program stop.

Most common I/O Instruction pick list Instruction builder Operator dialogs Language Date and time Power on sequence EM stop sequence Main start sequence Program start sequence Program stop sequence

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Configuration
Working space Additional axes Brake delay time I/O signals

Description
Working space limitations. Number, type, common drive unit, mechanical units. Time before brakes are engaged. 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). Configuration.

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

Serial communication

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

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1.7 Programming
1.7.1 Introduction
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 immediately take effect in the robot memory).

General

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 without 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 additional axes.

Stop point

Fly-by point (A)

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.

Pos
A

Description
User-definable distance (in mm).

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 automatically downloaded using a program instruction. The complete program or parts of programs can be transferred to/from the network or a portable flash memory connected 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 commands. 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

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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 possible 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 controlled 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 Exception handling


1.10.1 Introduction

General

Many advanced features are available to make fast error recovery possible. Characteristic 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 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
On-line supervision

Detail
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, temperatures, 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 Fault tracing support Error message

Built-in self-test Computer status LEDs and console (serial channel) Displayed in plain language The message includes the reason for the fault and suggests recovery action. 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. Commands and service programs in RAPID to test units and functions.

Faults and major events are logged and timestamped. Manual test

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Function
Properties Safety chain LEDs

Detail
Detailed properties of hard and software in the controller are available for viewing from pendant or RobotStudio Online. On the panel unit (std) On the Control Module operators panel (optionally).

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.

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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 performance 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

(A)

X (B)

Y (C) X

(D) Z (E) Z Y Y (F) Z X X

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

Pos
A B C D E F

Description
Tool Center Point (TCP) Tool coordinates Base coordinates Object coordinates User coordinates World coordinates

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Coordinate systems

System
Coordinate systems

Description
RobotWare includes a very powerful concept of multiple coordinate systems that facilitates jogging, program adjustment, copying between robots, off-line programming, sensor 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). The world coordinate system defines a reference to the floor, which is the starting point for the other coordinate systems. 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. The base coordinate system is attached to the base mounting surface of the robot. The tool coordinate system specifies the tools centre point and orientation. The user coordinate system specifies the position of a fixture or workpiece manipulator. 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 tools 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. 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. The robot can move in any of the following ways: -Joint motion (all axes move individually and reach the programmed 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 - 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. 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.

World coordinate system

Base coordinate system Tool coordinate system User coordinate system Object coordinate system

Stationary TCP

Program execution

Soft servo

Location

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System
Jogging

Description
The robot can be manually operated in any one of the following 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 FlexPendant. The robot can pass through singular points in a controlled way, i.e. points where two axes coincide. The behaviour of the motion system is continuously monitored as regards position and speed level to detect abnormal conditions and quickly stop the robot if something is not OK. A further monitoring function, Collision Detection, is optional (see option RobotWare-Collision Detection). Very flexible possibilities to configure additional motors. Includes for instance high performance coordination with robot movement and shared drive unit for several motors. 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.

Singularity handling Motion supervision

Additional motors

Big inertia

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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 robots motors. See Figure 10.

Figure 10 Standard Drive Module.

An additional drive module can be connected for control of up to eight or nine additional 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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Note that an additional Drive Module for additional motors reduces the maximum number of additional robots to two. See MultiMove (optional) on page 20.

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 IRB 140-1400


Basic specification

Drive Module
3 x A drive 3 x B drive

IRB 2400
Basic specification

Drive Module
2 x E drive 2 x C drive 2 x B drive

IRB 340
Basic specification

Drive Module
3 x E drive 1 x C drive

IRB 4400/940
Basic specification

Drive Module
3 x T drive 3 x G drive

IRB 6600/7600
Basic specification

Drive Module
3 x V drive 3 x W drive

Drive unit type


W V T G E

Continous current (Amp rms)


30 14.5 25 16.5 12

Max current (Amp rms)


55 25 38 26 19

Voltage to motor (V rms)


400-480* 400-480* 260 260 260

Max bus voltage (V DC)


790 790 430 430 430

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Drive unit type


C B A

Continous current (Amp rms)


9 5.5 2

Max current (Amp rms)


12 6.7 3.3

Voltage to motor (V rms)


260 260 260

Max bus voltage (V DC)


430 430 430

*) 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 example, 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.
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 I/O System


1.14.1 Introduction

Fieldbuses

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


Option
DeviceNet Profibus DP Interbus

Description
PCI card certified by ABB included PCI card certified by ABB included PCI card certified by ABB included

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 functionality. 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 maximum 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.
Digital inputs
Motors On Motors On and Start Motors Off Load and Start Interrupt

Digital outputs
Auto on Blocked I/O Cycle On Emergency Stop Execution Error Rev.2

Analog outputs
TCP Speed TCP Speed Reference

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Digital inputs
Start Start at main Stop Stop at end of Cycle Stop at end of Instruction Reset Execution Error signal Reset Emergency Stop System Restart

Digital outputs
Motors Off State Motors On State Motors Off Motors On Motion Supervision On Motion Supervision Triggered Power Fail Error Path Return Region Error Runchain Ok

Analog outputs

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

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 number 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.

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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)

A IRC5

B C

D C F F F F G F H F C F F

E
Figure 12 Example of a DeviceNet bus.

Pos
A B C D E F G H

Description
Terminator Trunk line Drop line Tap Zero drop Node Short drop T-connector

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

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Data rate for ABB DeviceNet I/O units is fixed at 500 Kbit/s.
Type of unit
Digital I/O 24 VDC Analog I/O AD Combi I/O Relay I/O Allen-Bradley Remote I/O gateway Interbus gateway Profibus DP gateway Encoder interface unit

DSQC
328A 355A 327A 332A 350A

Option In no.
716-1 719-1 717-1 718-1 721-1 16 16 16

Out
16

Voltage Voltage Current Power inputs output output supply


Internal/ External1 4 3 2 1 Internal Internal/ External1 Internal/ External2

16 16

1282 128

351A 352A 377A

722-1 720-1 725-1

642

64

1282 128 1

1. The digital signals are supplied in groups, each group having 8 inputs or outputs 2. To calculate the number of logical signals, add 2 status signals

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
Option 727-1 DSQC 608 Option 727-2 2 x DSQC 608

Name
Customer I/O power supply

Data
Output voltage 24 V DC -0% +10%. 0 V directly grounded to chassis. Rated continuous load 8A Output over current protection <12A Output over voltage protection <31.2V Output hold-up >20ms Output noise/ripple <200mV p-p Output voltage 24 V DC -1% +5%, galvanic isolated from chassis. Rated continuous load 4A Output over load protection <100VA Output over voltage protection <29V Output hold-up>20ms Output noise/ripple <25V p-p Fulfils Limited Power Source NEC Class 2 requirement

Option 728-1 DSQC 634

DeviceNet power supply

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

Signal data Digital inputs (option 716-1, 717-1, 718-1)


24 V DC Optically-isolated Rated voltage Logical voltage levels Input current at rated input voltage Potential difference Time delays Time variations 24 V DC 1 15 to 35 V 0 -35 to 5 V 6 mA max. 500 V hardware 5-15 ms software 3 ms 2 ms

Values

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


24 V DC Optically-isolated Voltage supply Rated voltage Logical voltage levels Output current Potential difference Time delays Time variations

Values
short-circuit protected, supply polarity protection 19 to 35 V 24 V DC 1 18 to 34 V 0 < 7 V max. 0.5 A max. 500 V hardware 1ms software 2ms 2 ms

Relay outputs (option 718-1)


Single pole relays with one make contact (normally open) Rated voltage Voltage range Output current Potential difference Time intervals

Values

24 V DC, 120 VAC 19 to 35 V DC 24 to 140 V AC max. 2 A max. 500V hardware (set signal) typical 13 ms hardware (reset signal) typical 8 ms software 4 ms

Analog inputs (option 719-1)


Voltage Input voltage Input impedance

Values
10 V >1 Mohm

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Analog inputs (option 719-1)


Resolution Accuracy

Values
0.61 mV (14 bits) 0.2% of input signal

Analog outputs (option 719-1)


VoltageOutput voltage Load impedance Resolution CurrentOutput current Load impedance Resolution Accuracy

Values
10 V min. 2 kohm 2.44 mV (12 bits) 4-20 mA min. 800 ohm 4.88 A (12 bits) 0.2% of output signal

Analog outputs (option 717-1)


Output voltage (galvanically isolated) Load impedance Resolution Accuracy Potential difference Time intervals

Values
0 to +10 V min. 2 kohm 2.44 mV (12 bits) 25 mV 0.5% of output voltage max. 500 V hardware 2.0 ms software 4 ms

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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.

(A)

(B)
Figure 13 Point-to-point communication

Pos
A B

Description

Temporary Ethernet Permanent Ethernet or serial

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

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H U B

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, computers and other equipment. The serial channel can be used at speeds up to 115 Kbit/s.

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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.

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2.1.1 Introduction

2 Specification of Variants and Options


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.

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2 Specification of Variants and Options


2.2.1 Introduction

2.2 Basic
2.2.1 Introduction

Safety compliance Option


429-1 UL/CSA

Description
The robot and the control system are certified by Underwriters 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. The robot and the control system comply with the European 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.

129-1 EU Electromagnetic Compatibility

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 permitted. The power cable is connected to the Drive Module via an industrial connector. 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.

Servo transformer Option


769-7 769-1 769-2 769-3 769-4 769-5 769-6

Voltage
200V 220V 400V 440V 480V 500V 600V

IRB 140
X X X X X X X

IRB 1400
X X X X X X X

IRB 2400
X X X X X X X

IRB 4400
X X X X X X X

IRB 340
X X X X X X X

IRB 6600
X X X X

IRB 7600
X X X X X X

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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.

Option
742-1

Description
Rotary switch in accordance with the standard in chapter 1.2 and IEC 3371, 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. Circuit breaker for rotary switch. A circuit breaker for short circuit protection of mains cables in the Drive Module. Circuit breaker approved in accordance with IEC 898, VDE 0660. Door interlock for rotary switch.

743-1

744-1

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.

Room temperature Option


708-1 708-2

Temperature
Room temperature up to 45oC (113oF) Room temperature up to 52oC (125oF)

Description
Standard design of the Control Module and Drive Module. Internal forced air circulation in the Control Module, increased fan capacity in the IRB 6600/IRB 7600 Drive Module.

Door lock insert

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

Option
739-1

Description
Standard, coin proof type, Screw driver required to operate

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

Option
739-2 739-3 739-4 739-5

Description
Square 7 mm outside EMKA DB Cylinder 3524 Doppelbart

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2.2.1 Introduction

Cabinet connector protection

Option
741-1 741-2

Connector
One connector cover Two connector covers

Description
The Drive Module connectors are protected. Both Control Module and Drive Module connectors are protected.

Manipulator cables

The manipulator cables consists of two cables.

Cable Type
Motor cable Measurement cable

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

Option
210-1 210-2 210-3 210-4 210-5 211-2 211-3

Description
3m 7m 15 m 22 m 30 m 22m 30 m

Remarks
only IRB 340

Not for IRB 140 Not for IRB 140 Only IRB 140 Only IRB 140

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2.3.1 Introduction

2.3 Control module


2.3.1 Introduction

Option
700-1

Controller
No control module

Description
When the robot is controlled from another controller in a Multi Move system, this option is selected. The control system consists of one Control Module and one Drive Module. They are delivered in one piece with inter cabling pre-installed.

700-2

Flexible Controller

FlexPendant

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

Option
701-1 701-3

Description
With 10 m cable 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. The option consists of a jumper connector to close the safety chains. This is required if a FlexPendant is not connected.

702-1

Connector plug

FlexPendant language

Three user interface languages can be stored in the pendant. English is always available, 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


644-1 644-2 644-3 644-4 644-5 644-6 644-7 644-8 644-9 644-10 644-11 3HAC 021785-001

Language
French German Spanish Italian Chinese Portugese Dutch Swedish Danish Czech Finnish Rev.2 55

2 Specification of Variants and Options


2.3.1 Introduction

Option
644-12 644-13

Language
Korean Japanese

Second additional language

Option
645-1 645-2 645-3 645-4 645-5 645-6 645-7 645-8 645-9 645-10 645-11 644-12 644-13

Language
French German Spanish Italian Chinese Portuguese Dutch Swedish Danish Czech Finnish Korean Japanese

Memory Option
705-1

Memory
Hard disc

Description
The standard 256 MB flash drive is replaced by a hard drive 20 GB or larger.

USB Flash disk interface Option


706-1

Description
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.

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2.3.1 Introduction

The following USB Flash drive types are verified:

Disk types
San Disk Cruzer Mini Iomega Mini

Values
128/256 MB 128 MB

Network connection Option


707-1

Description
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.

Optional PCI cards

Four slots are available for different usage.

Option
709-1

Description
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 Application manual - DeviceNet. Occupies one PCI slot. Occupies two PCI slots. 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. Profibus DP m/s The hardware of the Profibus DP field bus consists of a master/slave unit, DSQC 510/637. The signals are connected to the board front (two 9pole 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.

709-2 710-1

DeviceNet m/s dual channels

711-1

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2.3.1 Introduction

Option
285-1

Description
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. 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 connected 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 normally 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 digital input and 160 digital output signals.

712-2

Interbus m/s optical fibre

712-1

Interbus m/s copper wire (9-pole D-sub connections) 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. Multiple serial ports Serial communication card DSQC 614 with two RS232 ports, COM2 and COM3. Occupies one PCI slot

185-1

713-1

RS 422/485 Option
714-1

Decription
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, from RS232 = 15 m to RS422/485 = 120 m.

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.

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2.3.1 Introduction

Option
730-1

Description
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 recommended.

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2.3.1 Introduction

DeviceNet I/O units

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

Option
716-1 717-1 718-1

Description
Digital 24 VDC I/O AD Combi I/O Digital I/O with relay outputs 16 inputs/16 outputs 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V) 16 inputs/16 outputs Relay outputs to be used when more current or voltage is required from the digital outputs. The inputs are not separated by relays. 4 inputs: 10V 4 outputs: 3x 10V, 1x4-20mA

719-1

Analog I/O

(A)

195

203
Figure 15 Dimensions for I/O units.

49

Pos
A

Description
EN 50022 mounting rail

DeviceNet gateway units

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

Option
720-1

Description
Profibus DP (DSQC 352A) Up to 128 digital inputs and 128 digital outputs 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).

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Option
721-1

Description
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). 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). 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 sensor. PickMaster conveyor tracking applications.

722-1

Interbus (DSQC 351A)

726-1

Encoder interface unit for conveyor tracking (DSQC 377A)

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 conveyor is not moving. Output signal: Open collector PNP output Voltage: 10 - 30 V (normally supplied by 24 VDC from DSQC 377A) Current: 50 - 100 mA Phase: 2 phase with 90 drgree phase shift Duty cycle: 50% Following encoder is verified: Lenord & Bauer GEL 262

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2.3.1 Introduction

(A)

170

115
Figure 16 Dimension for gateway units.

49

Pos
A

Description
EN 50022 mounting rail

Power supply (for customer I/O) Option


727-1 727-2 728-1

Description
24 V 8 Amps for bus and process supply 24 V 16 Amps for bus and process supply 24 V 4 Amps for DeviceNet bus supply Fulfils Limited Power Source NEC Class 2 requirement

Safety signals interface Option


731-1 731-2

Connection
Internal connection External connection

Description
The signals are connected directly to screw terminals at the panel board inside the cabinet 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.

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2.3.1 Introduction

IMM (Injection Mould Machines) interface

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

Option
671-2

Type
Euromap 67

Description
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. 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 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.

671-1

Euromap 12

671-3

SPI (Society of Plastics Industry)

Additional cables

Additional cables for the different standards are available.

Option
673-1 673-2

Description
10 m 15 m

To facilitate the configuration of the IO-interface in the controller, specific IO-configuration 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.

IRC5 Controller

Em12

SPI

Em67

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

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2.3.1 Introduction

Operators interface

The operators panel can be installed in different ways.

Option
733-1 733-2 733-3

Standard
Standard External External

Description
On the front of the cabinet. Mounted in a box. See Figure 18. To be mounted in a separate operators unit (enclosure not supplied).

Figure 18 External control panel mounted in a box.

Operators external panel cables

Option
734-1 734-2 734-3

Length
15 m 22 m 30 m

Operating mode selector (key switch)

Option
735-1 735-2 735-3 735-4

Standard
Standard Standard Additional contact Additional contact

Description
3 modes: manual, manual full speed and automatic. 2 modes: manual and automatic. 3 modes manual, manual full speed and automatic. 2 modes: manual and automatic.

The three modes types do not comply with UL safety standards. Additional contact means two extra dry contacts for customer usage.

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2.3.1 Introduction

OPTION

-S21.1.X1 3 -245 -244

2 -243

1 -246

4 -241

7 -240

6 -239

5 -242 EXT.COMMON1

EXT.COMMON2

EXT MAN FS2

Mode Selector 21.1


6 12 10

2 4 8 1

18 22 24 17

14

16 20 13

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.

Option
736-1 736-2

Outlet
230 V outlet in accordance with DIN VDE 0620 120 V outlet in accordance with American standard

Description
single socket suitable for EU countries single socket, Harvey Hubble.

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).

Option
737-1

Status
Status

Description
LEDs in front

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EXT MAN FS1

EX T.AUTO2

EXT.AUTO1

EXT.MAN2

EXT.MAN1

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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

Option
766-1

Description
Prepared for additional drive units

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

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

Options
753-1, 754-1, 755-1 753-2, 754-2, 755-2 753-3, 754-3, 755-3

Description
Drive unit C Drive unit T Drive unit U

Drive units for IRB 4400 (maximum two)

Options
770-1, 771-1 770-2, 771-2 770-3, 771-3

Description
Drive unit C Drive unit T Drive unit U

Drive units for IRB 6600, IRB 7600 (maximum two

Options
770-4, 771-4

Description
Drive unit W

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2.4.1 Introduction

Drive unit capacity Drive unit type


W U T C

Continous current (Amp rms)


30 36 25 9

Max current (Amp rms)


55 55 38 12

Voltage to motor (V rms)


400-480* 260 260 260

Max bus DC voltage


790 430 430 430

*) Depending on line voltage and robot type. Bus voltage is 480V except for IRB6600 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.

Option
757-1

Description
Serial measurement board as separate unit for external assembly

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.

Option
761-1

Description
Cable length 4 m to be used when two Drive Modules are stacked with the Control Module on top. Cable length 30 m. The cable can easily be shortened by means of normal installation tools
CM DM DM
CM DM

(4 m)

761-3

(30 m) DM

Duty time counter (DTC) Option


767-1

Description
Indicates the operating time for the manipulator (released brakes).

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

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2.4.1 Introduction

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Index

A absolute measurement, 29 additional Motors, 38 Allen-Bradley Remote I/O, 44, 61 analog signals, 42 authorization, 18, 24 automatic operation, 29 B backup, 21 bumps, 23 C Cabinet connector protection, 54 collision detection, 11 communication, 47 computer system backup, 24 concurrent I/O, 42 configuration, 24 configuration editor, 18 connection, Ethernet, 12 connection, FlexPendant, 7 connection, network, 57 connection, USB, 12 control module, 7 cooling device, 7 coordinate systems, 35 cross connections, 42 D diagnostics, 32 digital signals, 42 DRAM memory, 21 drive module, 7, 14 drive units, 66 E editing, position, 28 editing, programs, 27 editing, system parameters, 17 Emergency, 13 emergency stop, 11 emergency stop button, 15 enabling device, 11, 16 Encoder, 61 Encoder interface unit, 44 event recorder, 17 exception handling, 31 explosive environments, 23 F fire safety, 11 flash disk memory, 21 FlexPendant, 15, 26 fly-by point, 27

H hold-to-run control, 11 humidity, 23 I I/O system, 41 I/O units, 44 installation, 23 Interbus, 44, 61 Interbus Slave, 41 interrupt, 41 J joystick, 15, 16 K key features, 18 L language, 24 M mains switch, 53 mains voltage, 52 maintenance, 32 mass memory, 21 memory, available, 21 memory, controllers program, 18 memory, extended, 21 motion, 34 MuliMove, 20 MultiMove, 11, 19 Multitasking, 42 N noise level, 7 O operating mode selector, 13 operating modes, 13 operating requirements, 23 operation, 12 operators external panel cables, 64 operators panel, 12 options, 51 over-speed protection, 11 P password, 24 PLC functionality, 42 position fixed I/O, 42 position programming, 27 production window, 29 Profibus, 57, 58, 60 Profibus DP, 41 program editor, 18 program, without interrupting production, 19 programming, 26
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Index

protective stop, 11 protective stop, delayed, 11 R RAPID Language, 30 Reduced speed, 11 RobotStudio, 19 RobotStudioOnline, 17, 26 S safe manual movements, 11 safety, 10 safety lamp, 11 serial communication, 47 service, 32 service outlet, 65 space requirements, 7 standards, 10 stop point, 27 structure, 7 system builder, 18 system signals, 41 T testing, program, 28 touch, 55 touch screen, 15 trap routines, 42 troubleshooting, 32 TrueMove, 34 U UPS, 21, 24 USB, 56 USB, flash disk interface, 21 V variants, 51 volume, 7 W windows, 15 working space, restricting, 11

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Index

3HAC 021785-001

Rev.2

71

Index

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ABB Automation Technologies AB Robotics S-721 68 VSTERS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592

3HAC 021785-001, Revision 2, en