3HAC021564-001_rev A_en.pdf - Technology

Getting Started 

IRC5 and RobotStudioOnline 

M2004 

Document ID: 3HAC021564-001 

Revision: A

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 Västerås 

Sweden

Table of Contents 

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 

1 Getting Started Procedures 5 

1.1 Overview, Getting started procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 

1.2 System start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 

1.3 Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 

1.3.1 Connecting a FlexPendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 

1.3.2 Installing RobotWare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 

1.3.3 Installing RobotStudioOnline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 

1.3.4 Getting and Installing a license key for RobotStudioOnline. . . . . . . . . . . . . . . . . . . . . 13 

1.4 Set Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 

1.4.1 Connecting a PC to the service port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 

1.4.2 Accessing a controller from RobotStudioOnline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 

1.4.3 Restart and select another system (X-start). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 

1.4.4 Using the boot application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 

1.5 Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 

1.5.1 Calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 

1.5.2 Updating revolution counters with FlexPendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 

1.5.3 Loading calibration data using RobotStudioOnline . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 

1.5.4 Loading calibration data using the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 

1.6 Restarting a controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 

2 General 35 

2.1 What you need to get the system started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 

2.2 What is a FlexPendant? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 

2.3 What is RobotStudioOnline?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 

2.4 What is RobotWare? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 

2.5 About the media pool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 

2.6 When to use the FlexPendant and RobotStudioOnline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 

2.7 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 

3HAC021564-001 Revision: A 3

References 

References 

General 

Please note that there is no information regarding safety aspects in this manual! 

In an effort to keep this manual short, there is no information regarding: 

• safe handling and operation of the equipment 

• generic reference information 

• detailed procedures 

This information may be found in the Product Manuals or the Operator's Manuals delivered 

with the robot system. 

4 3HAC021564-001 Revision: A

1 Getting Started Procedures 

1.1. Overview, Getting started procedures 


1.1. Overview, Getting started procedures 

Overview 

This chapter details how to perform specific actions designed to start the system up for the 

first time. 

The chapter is divided into sections to facilitate understanding the start up process. 



1.2. System start up 


Preconditions 

This instruction details the main steps required to start the system when the power has been 

switched off. 

All information is based on the assumption that working system software has already been 

installed on the robot controller, as the case would be at first start-up directly after delivery. 

Note that there may be more information available than the one referred to in the procedure. 

Chapters Controller and FlexPendant in the Operator's manual - IRC5 with FlexPendant or 

chapter Detailed procedures in the Getting started - IRC5 and RobotStudio Online document 

contain detailed information about how to use the system. 

System start up 

This procedure details all required steps to start the system for the first time. For everyday 

startup, step 4 is normally the only required step. 

Some reference information may be given in column Info in the table below.. 

Step Action Info 

1. Install the robot equipment. Mechanical installation and electrical connections 

between manipulator and controller cabinet is 

described in the Product Manual of the robot and 

controller respectively. 

2. Make sure the safety circuits 

of the system are properly 

connected to the robot cell or 

have jumper connections 

installed (if required). 

3. Connect the FlexPendant to 

the controller cabinet. 

How to connect the safety circuits is detailed in the 

robot Product Manual. 

The FlexPendant and its major parts and functions 

are detailed in section What is a FlexPendant? on 

page 39. 

How to connect the FlexPendant to the cabinet is 

detailed in section Connecting a FlexPendant on 

page 9. 

4. Switch the power on. Use the main switch on the control module. 





5. If the controller or manipulator 

have been replaced with spare 

parts, make sure the 

calibration values, revolution 

counters and serial numbers 

are updated correctly. 

6. This step is only required if the 

robot system will be connected 

to a network. 

Perform an X-start. 

The Boot Application is 

started. 

7. This step is only required if the 

robot system will be connected 

to a network. 

Use the boot application to: 

• set the IP address of 

the controller cabinet 

• set the network 

connections 

• select the system 

• restart the system 

The system is restarted. 

8. Install RobotStudio Online on a 

PC. 

9. Connect the controller to a PC 

(through the service port) or to 

the network (if used). 

Normally, only the revolution counters require 

updating, which is to be performed as detailed in 

section Updating revolution counters with 

FlexPendant on page 26. 

If required, transfer the calibration data from the 

serial measurement board as detailed in Serial 

Measurement Board memory for systems without 

the AbsAcc option. 

If required, enter the calibration data as detailed in 

Loading calibration data using RobotStudioOnline 

on page 29for systems with the AbsAcc option. 

Detailed in section Restart and select another 

system (X-start) on page 19. 

How to use the boot application is detailed in 

section Using the boot application on page 20. 

At this point, a single system is available. 

Proceed as detailed in section Installing 

RobotStudioOnline on page 12or in the Operator’s 

manual - RobotStudioOnline. 

RobotStudio Online is used to create a system to run 

on the controller, but at this point (prior to the first 

start-up) a system is already installed by the 

manufacturer. 

Proceed as detailed in section Connecting a PC to 

the service port on page 15. 

Also see sectionSet up a network connection. 





10. Start RobotStudio Online on the 

PC. 

11. Restart the controller. 

12. The robot system is now ready 

for operation. 

Proceed as detailed in section Accessing a 

controller from RobotStudioOnline on page 17or in 

the Operator’s manual - RobotStudioOnline. 



1.3.1. Connecting a FlexPendant 

1.3 Installation Procedures 


Location 

The FlexPendant connector is located as shown below. 

xx0400000729 

A 

FlexPendant socket connector 

Procedure 

Step Action Illustration 

1. Locate the FlexPendant socket 

connector on the control module. 

xx0400000931 

• O: FlexPendant connector 

(A22.X1) 





2. Plug in the FlexPendant cable 

connector. 

3. Screw the connector lock ring firmly by 

turning it clockwise. 



1.3.2. Installing RobotWare 

1.3.2. Installing RobotWare 

Overview 

Installing RobotWare creates a media pool, which is a folder on the PC with the data 

necessary for creating and modifying robot systems. 

When do you need RobotWare? 

RobotWare must be installed if you want to create or modify robot systems. 

Install RobotWare 

To install RobotWare to media pool on the PC: 

1. Insert the Robot's software CD in the computer. 

• If a menu for the CD is opened automatically, continue with step 5. 

• If no menu for the CD is opened, continue with step 2. 

2. On the Start menu, click Run. 

3. In the Open box, type the drive letter for your CD drive followed by :\launch.exe. 

Example: If your CD drive has the letter D, then type D:\launch.exe 

4. Click OK. 

5. Select language for the CD menu. 

6. On the CD menu, click Install. 

7. On the CD menu, click RobotWare . This opens an installation guide, which will guide 

you through the rest of the installation. 

Follow the instructions in the wizard. 



1.3.3. Installing RobotStudioOnline 

1.3.3. Installing RobotStudio Online 

Overview 

The Installation is made from an installation wizard, which will guide you through the 

installation. 

Install the software 

To install the RobotStudio Online software: 

1. Insert the Robot's software CD in the PC. 

• If a menu for the CD is opened automatically, continue with step 5. 

• If no menu for the CD is opened, continue with step 2. 

2. On the Start menu, click Run . 

3. In the Open box, type the drive letter for your CD drive followed by :\launch.exe . 

Example: If your CD drive has the letter D, then type D:\launch.exe 

4. Click OK . 

5. Select language for the CD menu. 

6. On the CD menu, click Install. 

7. On the installation menu, click RobotStudioOnline . This opens the Installation wizard, 

which will guide you through the rest of the software installation. 

Follow the instructions in the Installation Wizard. 

Result 

You have now installed RobotStudio Online on the PC. The next steps are to install a license 

key and connect the PC to a Robot. For creating and modifying robot systems, you also have 

to install RobotWare. For further information, seeGetting and Installing a license key for 

RobotStudioOnline on page 13, Connecting a PC to a robot and Installing RobotWare on 

page 11, respectively. 



1.3.4. Getting and Installing a license key for RobotStudioOnline 

1.3.4. Getting and Installing a license key for RobotStudio Online 

Overview 

Getting and installing a license key is necessary for running RobotStudio Online after the demo 

period has expired. 

The licensing is made in two steps, where the first is to request a license key and the second 

is to install the license key on the PC. 

Unique license key 

The license key is unique for each PC. Therefore, the License Key Request wizard must be 

filled out using the PC on which RobotStudio Online is to be run. 

Request a license key 

To request a license key: 

1. On the Start menu, point to Programs , ABB Industrial IT , Robotics IT, Licensing 

and then select License Key Request Wizard . 

2. Follow the instructions in the wizard and enter the requested information. When the 

wizard is completed, a license key request file is saved to a file on your PC. Its name is 

LicenseKeyRequest-RobotStudio Online-unique number.txt, located on the 

desktop. 

3. Attach the license key request file to an E-mail and send it to oftwarefactory@se.abb.com. 

The file must be attached to the E-mail (not copied into the body of the E-mail) and have 

the extension txt (as it is created), otherwise the license key request will fail the 

processing. 

A license key file will then be sent by E-mail to the E-mail address specified in the 

License request Wizard within a few minutes. 

Install the license key 

When you have received the e-mail with the license key file: 

1. Detach the license key file from the e-mail and save it to a file on your PC. For 

information about how to detach files from an e-mail, see the help for your e-mail 

program. 

2. Double-click the license key file. This opens the License Install Wizard. 



1.3.4. Getting and Installing a license key for RobotStudioOnline 

3. In the License Install Wizard, follow the instructions in the wizard. 

Result 

You can now run RobotStudio Online . To work with a robot controller, you also must connect 

the PC to the robot, either through a network or directly to the controllers service port. See 

Connecting a PC to a robot for detailed information. For creating and modifying robot 

systems, you must also install RobotWare. For further information, see Installing RobotWare 

on page 11. 



1.4.1. Connecting a PC to the service port 

1.4 Set Up Procedures 


Procedure 

NOTE! 

The service port shall only be used for direct connection to a PC as described in this 

procedure. It must not be connected to a LAN (local area network), since it has a DHCP server 

that automatically distributes IP addresses to all units connected to the LAN. Contact your 

network administrator if you need more information. 

CAUTION! 

When a boot cable is connected to the service port and the service hatch is opened, the 

controller will not comply with the requirements of protection class IP54. 


1. Make sure the PC’s network settings are 

configured correctly. 

2. Use the delivered category 5 Ethernet 

crossover boot cable with RJ45 connectors. 

Proceed as detailed in section 

Network settings for a PC connected 

to the service port or the Getting 

Started Manual 

The cable is delivered in the 

RobotWare product box. 





3. Connect the network cable to the network 

port of your PC 

4. Connect the boot cable to the service port, 

placed on the control module front. 

xx0400000844 

• A: network port 

The placement of the network port 

may vary depending on the pc model. 

Placeholder 

• A: service port. 



1.4.2. Accessing a controller from RobotStudioOnline 

1.4.2. Accessing a controller from RobotStudio Online 

Overview 

This information topic describes an easy way to access a single robot controller from 

RobotStudio Online when the PC is connected to the controller's service port. 

You can also create a robot view and add controllers to it manually, which is useful when one 

or several controllers are connected to the same Ethernet network as RobotStudio Online . For 

more information about connecting to controllers over an ethernet network, see Creating a 

robot view and Adding a controller to a robot view respectivelyin the 

RobotStudio Online operating manual. 

Prerequisites 

The network settings must be correct on the PC. That is, either shall DHCP be enabled or the 

IP address shall have a specific value. See Network settings for connecting a PC to a robot 

for detailed information 

The PC must be connected to the robot's service port before RobotStudio Online is started. See 

Connecting a PC to the service port on page 15 for detailed information. 

Connect to the controller 

To connect the controller to RobotStudio Online : 

1. Make sure the PC is connected to the controller's service port and that the controller is 

running. 

2. Start RobotStudio Online by clicking Windows’ Start button, pointing to Programs, ABB 

Industrial IT, Robotics IT, RobotStudio Online and then selecting RobotStudio 

Online. 

3. On the Tools menu of RobotStudio Online , click Connect to Service port. 

The controller is now added to a robot view in RobotStudio Online . Now continue with 

requesting Write access to the controller in order to work with it. 

Request write access 

To request write access to a controller from RobotStudio Online : 

1. Select the controller in the robot view. 

2. On the Controller menu, click Request Write access. 



1.4.2. Accessing a controller from RobotStudioOnline 

If the controller is in mode 

Auto 

Manual 

Then 

You will now get Write Access if it’s available. 

You have to grant remote Write Access from 

the FlexPendant in order to get Write Access 

from RobotStudio Online . See Operator’s 

Manual - IRC5 with FlexPendant for detailed 

instructions. 

Result 

The controller is added to a new robot view in RobotStudio Online and you now have access to 

work with it. See About robot viewsin the RobotStudio Online operating manual for more 

information. 



1.4.3. Restart and select another system (X-start) 

1.4.3. Restart and select another system (X-start) 

Restart and select another system 

This section describes how to restart and select another system. 


1. Make sure the power to the controller cabinet is 

switched on. 

2. On the ABBmenu, tap Restart. 

The restart dialog is displayed. 

3. Tap Advanced... to select restart method. 

The select restart method dialog is displayed. 

4. Tap X-start, then tap OK. 

A dialog letting you confirm that you really want to 

restart is displayed. 

5. Tap X-Start to restart the controller. 

The controller is restarted. After the startup procedure 

the boot application is started. 

6. Use the boot application to select system. How to use the boot 

application is detailed in 

Using the boot application 

on page 20. 

7. Tap Close, then OK to return to the boot application. 

8. Tap Restart to restart the controller using the 

selected system. 



1.4.4. Using the boot application 



The boot application is a basic program mainly used to start up the system when no 

RobotWare is installed. 

Purpose of the program 

The application is already installed in the controller at delivery and may be used to: 

• install systems 

• set or check network settings 

• select a system/switch between systems from the mass storage memory 

• load the system from USB memory units or network connections 

The illustration shows the boot application main screen with its three major buttons. The 

functions available behind each button are described below. 

en0400000894 




Install system 

This procedure may take several minutes. 

Step Action Info/illustration 

1. You may reach the boot application by 

performing an X-start. 

2. In the boot application, tap Install 

System. 

A dialog box is displayed urging you to 

connect a USB memory. 

3. Connect a USB memory containing a 

system to the computer unit USB port. 

4. Tap Continue to proceed. 

Tap Cancel to abort. 

The system is read from the USB 

memory, and a dialog box is displayed, 

urging you to restart. 

5. Tap OK. 

6. Tap Restart Controller. 

A dialog box is displayed. 

7. Tap OK again. 

8. Tap Select System and select the 

system previously installed from the 

USB memory. 

9. Tap Close. 


10. Tap OK. 

11. Tap Restart Controller to restart the 

controller using the system installed 

from the USB memory. 


12. Tap OK. 

How to perform an X-start is detailed in 

section Restart and select another system 

(X-start) on page 19. 

How to load a system to the USB memory 

is detailed in section Creating boot media. 

The computer unit USB port is shown in 

section Connecting a USB memory to the 

computer unit. 

The USB memory may be disconnected at 

this point. 

This is detailed in section Select System 

on page 23. 

This is detailed in section Restart 

Controller on page 23. 




Settings 


1. You may reach the boot application by performing an 

X-start. 

2. In the boot application, tap Settings. 

A screen is shown: 

How to perform an X-start is 

detailed in section Restart 

and select another system 



3. Make the appropriate selections: 

• Use no IP address 

• Obtain IP address automatically 

• Use the following settings 

Use the numerical keyboard to enter the desired 

values. 

4. Tap Service PC information to display network 

settings to be used when connection a service PC to 

the controller's service port. 

5. Tap FlexPendant to display FlexPendant software 

versions. 

Tap Advanced to display the boot loader version. 

How to make these 

selections is detailed in 

section Set up the network 

connections. 




Select System 



X-start. 

2. In the boot application, tap Select System. 

A dialog box is displayed showing the available 

installed systems. 

3. Tap the system to be selected and then Select. 

The selected system is displayed in the box Selected 

System. 

4. Tap Close. 

A dialog box is shown urging you to restart to be able 

to use the selected system. 





Restart Controller 



X-start. 

2. In the boot application, tap Restart System. 

A dialog box is displayed specifying the selected 

system. 

3. Tap OK to restart using the selected system or 

Cancel to abort. 







1.5.1. Calibration procedure 

1.5 Calibration Procedures 


Overview 

This section details the common starting point when calibrating an ABB IRC5 robot. 

Depending on which type of calibration to perform, references will be given below. 

Normally, a robot is delivered with the standard calibration data stored on the Serial 

Measurement Board (SMB). For robots delivered with the Absolute Accuracy option, the 

AbsAcc calibration data is delivered on a diskette. 

Absolute Accuracy calibration data must be manually entered into the robot controller. The 

calibration data must be loaded from the absacc.cfg file, which is delivered with the robot. 

The diskette includes absacc.cfg for MultiMove as well as single robot applications. 

Depending on robot number in MultiMove, pick the correct folder (“IRC5_rob1”... 

“IRC5_rob4”). Single robot applications must use the “IRC5_rob1”-data. 

Entering motor calibration values may be done in one of three ways: 

• From a diskette, using the FlexPendant (as detailed in section Loading calibration 

data using the FlexPendant on page 30). 

• From a diskette, using RobotStudioOnline (as detailed in section Loading calibration 

data using RobotStudioOnline on page 29). 

All robots will require updating the revolution counters at first start-up as detailed in section 

Updating revolution counters with FlexPendant on page 26 

Make sure the absacc.cfg has been loaded before revolution counter are updated. 




Initial procedur 


1. On the ABB menu, tap Calibration . 

All mechanical units connected to the system are shown along 

with their calibration status. 

2. Tap the mechanical unit in question. 

A screen is displayed: 


3. The illustration shows the screen displayed after tapping 

Calibration. Available alternatives are: 

Rev. Counters: 

• Update revolution counters... This procedure is 

detailed in section Storing the revolution counter 

setting on page 26. 

Calib. parameters: 

• Edit motor calibration offset... This procedure is 

detailed in section Edit motor calibration offset... . 

• Fine calibration... WARNING! This procedure is 

detailed in section Fine calibration... . 

SMB Memory: 

• All functions available under this button are detailed in 

section Serial Measurement Board memory. 



1.5.2. Updating revolution counters with FlexPendant 



This section details how to perform a rough calibration of each robot axis, i.e. updating the 

revolution counter value for each axis, using the FlexPendant. 

For robots using the Absolute Accuracy option, the calibration data file absacc.cfg must be 

loaded first. 

Manually running the robot to the calibration position 

This procedure details the first step when updating the revolution counter; manually running 

the robot to the calibration position. 

Step Action Note 

1. Select axis-by-axis motion mode. 

2. Jog the robot so that the calibration marks lie 

within the tolerance zone. 

3. When all axes are positioned, store the 

revolution counter settings. 

Shown in section Calibration scales 

and correct axis positions. 

Detailed in sections: 

Storing the revolution counter setting 

on page 26 (RobotWare 5.0). 

Storing the revolution counter setting 

This procedure details the second step when updating the revolution counter; storing the 

revolution counter setting. 




Step 

Action 

1. On the ABB menu, tap Calibration. 

All mechanical units connected to the system are shown along with their calibration 

status. 

2. Tap the mechanical unit in question. 

A screen is displayed: tap Rev. Counters. 


3. Tap Update revolution counters.... 

A dialog box is displayed, warning that updating the revolution counters may change 

programmed robot positions: 

• Tap Yes to update the revolution counters. 

• Tap No to cancel updating the revolution counters. 

Tapping Yes displays the axis selection window. 

4. Select the axis to have its revolution counter updated by: 

• Ticking in the box to the left 

• Tapping Select all to update all axes. 

Then tap Update. 




Step 

Action 

5. A dialog box is displayed, warning that the updating operation cannot be undone: 

• Tap Update to proceed with updating the revolution counters. 

• Tap Cancel to cancel updating the revolution counters. 

Tapping Update updates the ticked revolution counters and removes the tick from 

the list of axes. 

6. 

- 

Caution! 

If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, 

which in turn may cause damage or injury! 

Check the calibration position very carefully after each update. 

See section Checking the calibration position. 



1.5.3. Loading calibration data using RobotStudioOnline 

1.5.3. Loading calibration data using RobotStudio Online 

Overview 

This section describes how to load calibration data for using RobotStudio Online . 

Load calibration data 

To load calibration data from the absacc.cfg file: 

1. Start RobotStudio Online and connect to the controller. See Accessing a controller from 

RobotStudioOnline on page 17 for details. 

2. In the robot view explorer, select the configuration node for the robot. 

3. On the Controller menu, point to Configuration and select Load Parameters. 

4. In the Select Mode dialog box, select Delete existing parameters before loading. 

5. Click Browse and select the absacc.cfg file for the robot. 

6. In the confirmation dialog box, click OK. 

7. Restart the controller by using the advanced restart option I-start. For detailed 

instructions, see Restarting a controller on page 31 

8. Copy the calibration data to the Serial measurement Board. For detailed instructions, see 

Serial Measurement Board. 



1.5.4. Loading calibration data using the FlexPendant 

1.5.4. Loading calibration data using the FlexPendant 

Overview 

This section describes how to load calibration data for using the FlexPendant. 

The calibration data is delivered on a diskette and will have to be moved to a USB memory 

or transferred to the controller through FTP. 

Load calibration data 

This section describes how to load the calibration data. 


1. On the ABB menu, tap Calibration and select a 

mechanical unit. Then tap Calib. parameters. 

2. Tap Load motor calibration.... 

A dialog box is displayed, warning that loading new 

calibration offset values may change programmed 

robot positions: 

• Tap Yes to proceed. 

• Tap No to cancel. 

3. For systems not running the Absolute Accuracy option 

the calibration data is normally stored on the serial 

measurement board (SMB). 

4. For system running the Absolute Accuracy option, the 

calibration data is normally delivered on a diskette. 

5. Select the file containing the Absolute Accuracy 

calibration data to be loaded into the system and tap 

OK. 

If a file containing invalid calibration data is selected, a 

dialog box will be displayed. Then re-select a file 

containing valid calibration data. 

Tapping Yes results in 

displaying a file selection 

window. 

In such case, Update data 

to controller from SMB 

memory as detailed in 

section Serial 

Measurement Board 

memory. 

In such case, proceed 

below. 

Absacc.cfg for systems 

with absolute accuracy 

measurement system 



1.6. Restarting a controller 


When to restart the controller 

Some operations requires a restart of the controller to take affect. When working in 

RobotStudio Online , you will be notified when a restart is necessary. 

Typically, you need to restart a controller when: 

• you want to run another system on the controller. 

• you have changed the robot's configuration, either with the Configuration Editor or by 

loading new configuration files. 

• you have added new options or hardware to the system. 

• A system failure has occurred. 

Prerequisites 

For restarting a controller, the following prerequisites must be met: 

• You must have Write access to the controller you are restarting. 

• For the advanced restart methods X-start and C-start, you must have access to the 

controller's teach pendant unit. 

Perform a warm restart 

This is the default restart method for activating changes when using RobotStudio Install . It 

restarts the controller with the current system, unless another system has been downloaded or 

restored from a backup. 

To restart a Controller: 

1. On the Controller menu, click Restart. A dialog box showing which system to restart 

with is displayed. This will be the current system, unless another system has been queued 

for restart. 

2. Click Restart. A dialog box with which you can confirm or cancel the restart is now 

displayed. 

3. Click Restart. The controller will now restart. To follow the restart progress, look at the 

Output Window. 




Restart the controller using advanced options 

To restart a Controller using any other restart method then the default warm start do this: 

1. On the Controller menu, click Restart. A dialog box showing which system to restart 

with is displayed. 

2. Click Advanced. A dialog box with different restart methods is displayed. 

3. Select the restart method to use and click OK. For detailed descriptions of the restart 

methods, see Advanced restart options on page 32. You will now return to the first dialog 

box. 

4. Click Restart. A dialog box showing the selected restart method is now displayed. 

5. Click Restart to confirm the selected restart method. 

6. For X-start or C-start continue with choosing which system to start using the boot 

application on the Flexpendant. See Operating manual - IRC5 with FlexPendant for more 

information about starting a system using the FlexPendant. 

Advanced restart options 

The controller can also be restarted with advanced options, with different possibilities to save 

and load data. 

To... 

Use the restart 

method... 

Restart the controller and activate changes made to the system. 

This is the default restart method for RobotStudio Install . 

Normally, it restarts the current system and activate changes made to the 

system's settings. If the system has been restored with a backup, this will 

be loaded as well. 

However, if another system has been downloaded to the controller, the 

controller will start with the new one. The current system will then be 

saved in its current state. 

Restart the controller with the current system and the default settings. 

This is the restart method for discarding changes made to the robot's 

configuration. It reverts the current system to the state it had when it was 

installed on the controller (an empty system). 

Warm start 

I-start 




To... 

Restart the controller with the current system and reinstall RAPID. 

This restart method deletes all RAPID program modules. It can be useful 

if the system has changed in such a way that the programs no longer are 

valid, for instance if system parameters used by the program are 

changed. 

Background tasks loaded automatically by the Task Modules system 

parameters are however restarted instead of deleted. 

Built in modules and RAPID system modules are not affected at all. 

Save current system and start boot application. 

This restart method saves the current system, with the current settings, 

and starts the boot application from which you can choose a new system 

to start with. You can also configure the controller's network settings from 

the boot application. 

Delete current system and start boot application. 

This restart method deletes the current system and starts the boot 

application from which you can choose a new system to start with. You 

can also configure the controller's network settings from the boot 

application. 

Restart the controller and accept the loaded backup as the current 

system. 

Use the restart 

method... 

P-start 

X-start 

C-start 

B-start 





2 General 

2.1. What you need to get the system started 



Illustration 

The illustration depicts, in a schematical way, the delivered parts, the software tools to install 

them and the basic work flow. 





Parts 

Part Description 

Described in: 

A Manipulator (a generic model shown) documents specified in 

section Product 

documentation, M2004 on 

page 50. 

B1 

B2 

C 

D 

E 

F 

G 

Control Module, IRC5, containing the control 

electronics of the robot system. 

Drive Module, IRC5, containing the power electronics 

of the robot system. 

RobotWare CD containing all robot software specified 

in section What is RobotWare? on page 45. 

Documentation CD containing documentation files as 

specified in section Product documentation, M2004 

on page 50. 

Robot system software being run by the robot 

controller. The system has been loaded into the 

controller from the server on the local area network. 

RobotStudio Online PC software installed on a PC. 

RobotStudio Online is used for loading the RobotWare 

software to the server as well as configuring the robot 

system and then loading the complete robot system 

into the robot controller. 

RobotStudio Online is used to perform tasks as defined 

in section When to use the FlexPendant and 

RobotStudioOnline on page 47. 

Calibration data diskette for systems running the 

Absolute Accuracy option only. Calibration data for 

systems without this option is normally delivered on 

the Serial Measurement Board (SMB). 

documents specified in 



page 50. 




page 50. 




page 50. 




page 50 and in section What 

is RobotStudioOnline? on 

page 44 





Described in: 

H 

J 

K 

M 

FlexPendant, which is connected to the controller, and 

is used to perform tasks as defined in section When to 

use the FlexPendant and RobotStudioOnline on page 

47. 

Server on network (not included in the delivery). This 

may be used for manually storing: 

• RobotWare 

• complete robot systems 

• documentation files 

In this context, the server may be considered as a 

storage unit used by the PC x, and may even be the 

same unit! 

The server may be disconnected when not 

transferring data between the server and controller! 

The server may be used for: 

• all RobotWare software may be manually 

stored using the PC and RobotStudio Online 

• complete configured system files may be 

manually stored after being created using the 

portable PC 

• all robot documentation files may be manually 

stored after being installed using the portable 

PC and RobotStudio Online 

In this context, the server may be considered as a 

storage unit used by the portable PC. 

RobotWare license key. The original key strings are 

printed on a papers (one for the Control Module and 

one for the Drive Module) delivered inside the drive 

module. 

If ordered, the RobotWare license key is installed on 

delivery, so no further actions are required to get the 

system running. 




page 50 and in section What 

is a FlexPendant? on page 39. 

In cases where the 

RobotWare was not installed 

at delivery, install RobotWare 

as detailed in section 

Installing RobotWare on page 

11 

A different license key is 

required for using 

RobotStudio Online , which is 

detailed in section Getting and 

Installing a license key for 

RobotStudioOnline on page 

13, 





Described in: 

N 

x 

Serial Measurement board (SMB) handling resolver 

data and storing calibration data. For systems not 

running the Absolute Accuracy option, the calibration 

data is stored on the SMB on delivery. 

PC (not included in the delivery), may even be the 

same unit as the server J, shown above! 

The PC may be disconnected when not transferring 

data between the server and controller! 

Handling data on the SMB is 

detailed in section Serial 

Measurement Board memory. 



2.2. What is a FlexPendant? 


Description of FlexPendant 

The FlexPendant (occasionally called TPU, or teach pendant unit) is a device for handling 

many of the functions involved with operating the robot system; running programs, jogging 

the manipulator, producing and editing application programs, etc. 

The FlexPendant consists of both hardware, such as buttons and joystick, and software. The 

FlexPendant is connected to the controller module through an integrated cable and connector. 

NOTE that specific functions may not be performed using the FlexPendant, but only through 

RobotStudio Online . How to perform these are specified in Operator's manual - 

RobotStudioOnline . 

Main parts 

These are the main parts on the FlexPendant. 





A 

B 

C 

D 

E 

F 

Connector 

Touch screen 

Emergency stop button 

Enabling device 

Joystick 

Hold-to-run buttons (two) 




Hardware buttons 

There are a number of dedicated hardware buttons on the FlexPendant. 


A 

B 

C 

D 

E 

F 

G 

H 

Programmable button 1. How to define its function is detailed in section 

Programmable keys in Operator's manual - IRC5 with FlexPendant. 







START button. Starts program execution.. 

STEP BACKWARDS button (BWD). Steps the program one instruction backwards. 

STEP FORWARDS button (FWD). Steps the program one instruction forwards. 

STOP button. Stops the program execution. 

Touch screen elements 

The illustration shows the touch screen elements of the FlexPendant touch screen. 





A 

B 

C 

D 

E 

F 

ABB menu 

Status bar 

ClientView 

Close button 

Task bar 

Quickset menu 

ABB menu 

Status bar 

The ABB menu contains programs, configurations, and applications. These are described in 

section ABB Menu in Operator's manual - IRC5 with FlexPendant. 

The Status bar displays information about the system and messages. This is described in 

section Status bar in Operator's manual - IRC5 with FlexPendant. 




ClientView 

The ClientView is the main area for displaying all available functions, this is where 

applications are displayed and used. 

Close button 

Tapping the close button closes the presently open view or application. 

Task bar 

The Task bar displays all open views and applications. 

Quickset menu 

The Quickset menu contains shortcuts to jogging and settings. This is described in section 

The Quickset menu in Operator's manual - IRC5 with FlexPendant. 



2.3. What is RobotStudioOnline? 

2.3. What is RobotStudio Online ? 

Overview 

RobotStudio Online is a PC software with which you work with robots, as a complement to 

working from the FlexPendant. RobotStudio Online is optimized for text based programming 

(suitable for programs with lot of logics or complex structure) and tasks related to managing 

the robot's system. 

RobotStudio Online can be installed on an ordinary computer running Windows 2000 or later. 

This computer can then be connected to one or several controllers by an Ethernet network, or 

to one single controller by the controller's service port connection. 

RobotStudio Online functionality 

The main entry to the functionality of RobotStudio Online 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. 

RobotStudio Online 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 Authorization. 

• Other tools for viewing and handling controller and system properties. 



2.4. What is RobotWare? 

2.4. What is RobotWare? 

Concept 

RobotWare is a generic term for all software to be installed in the robot system designed to 

operate the robot. 

RobotWare is installed and stored in the Media Pool folder on a PC/server. The media pool is 

described in section About the media pool on page 46. 

RobotWare is delivered on a CD and this contains software for all available models, options 

and such. 

However, a RobotWare license key, required to access the software, is delivered: 

• on a diskette 

• as a characted string printed on a piece of paper delivered with the controller cabinet. 

When adding functionality at a later date, a new license key is required to access the 

functions. The key is available from your local ABB representative. 



2.5. About the media pool 

2.5. About the media pool 

Overview 

The media pool is a folder on your PC that contains RobotWare programs and options. It is 

from the Media Pool you select programs and options when building systems. 

The default media pool 

If RobotWare is installed with default settings on the PC, the default media pool is located in 

the C:\Program Files\ABB Industrial IT\Robotics IT folder. 

Customized media pools 

You can create customized media pools by creating new folders to which you copy 

RobotWare files from existing media pools. You can also update or modify a media pool by 

importing new parts of RobotWare using the Import System Tool in RobotStudio Online . 

In RobotStudio Online , you then choose which media pool to use when creating new systems. 

Related information 

See Installing RobotWare on page 11 for information about installing the default media pool. 



2.6. When to use the FlexPendant and RobotStudioOnline 

2.6. When to use the FlexPendant and RobotStudio Online 

Overview 

For operating and managing the robot, you either use the FlexPendant or 

RobotStudio Online .The FlexPendant is optimized for tasks related to robot motions and 

ordinary operation and RobotStudio Online is optimized for configuration, programming and 

other tasks not related to the daily operation. 

Start, restart and shut down the controller 

To... 

Use... 

Start the controller. The power switch on the controller's front panel . 

Restart the controller. The FlexPendant, RobotStudio Online or the power switch 

on the controller's front panel . 

Shut down the controller. The power switch on the controller's front panel. 

Run and control robot programs 

To... 

Start or stop a robot program. 

Use... 

The FlexPendant 

Communicate with the controller 

To... 

Acknowledge events. 

View and save the controller's 

event logs. 

Back up the controller's 

software to files on the PC or 

a server. 

Back up the controller's 

software to files on the 

controller 

Transfer files between the 

controller and network drives. 

Use... 

The FlexPendant. 

RobotStudio Online or the FlexPendant. 

RobotStudio Online. 






Program a robot 

To... 

Create or edit robot programs 

in a flexible way. This is 

suitable for complex programs 

with a lot of logic, I/O signals 

or action instructions. 

Create or edit a robot program 

in a supportive way. This is 

suitable for programs that 

mostly consist of move 

instructions. 

Add or edit robot positions. 

Modify robot positions. 

Use... 

RobotStudio Online to create the program's structure and 

most of the source code and the FlexPendant to store robot 

positions and make final adjustments to the program. 

When programming, RobotStudio Online provides the following 

advantages: 

• A text editor optimized for RAPID code, with auto-text 

and tool-tip information about instructions and 

parameters. 

• Program check with program error marking. 

• Close access to configuration and I/O editing. 


When programming, the FlexPendant provides the following 

advantages: 

• Instruction pick lists 

• Program check and debug while writing 

• Possibility to create robot positions while 

programming 



Configure the robot's system parameters 

To... 

Edit the system parameters of 

the running system. 

Save the robot's system 

parameters as configuration 

files. 

Load system parameters from 

configuration files to the 

running system. 

Load calibration data. 

Use... 

RobotStudio Online or the FlexPendant 







Create, modify and install systems 

To... 

Create or modify a system. 

Install a system on a 

controller. 

Use... 

RobotStudio Online together with RobotWare and a valid 

RobotWare Key. 


Related information 

The table below specifies which manuals to read, when performing the various tasks referred 

to: 

Recommended use... for details, see the manual... Document number 

FlexPendant 

Operator’s manual - IRC5 with 3HAC 16590-1 

FlexPendant 

RobotStudioOnline Operator’s Manual - 

RobotStudio Online 3HAC 18236-1 



2.7. Product documentation, M2004 



The robot documentation may be divided into a number of categories. This listing is based on 

the type of information contained within the documents, regardless of whether the products 

are standard or optional. This means that any given delivery of robot products will not contain 

all documents listed, only the ones pertaining to the equipment delivered. 

However, all documents listed may be ordered from ABB. The documents listed are valid for 

M2004 robot systems. 

Hardware manuals 

All hardware, robots and controller cabinets, will be delivered with a Product manual which 

is divided into two parts: 

Product manual, procedures 

• Safety information 

• Installation and commissioning (descriptions of mechanical installation, electrical 

connections and loading system software) 

• Maintenance (descriptions of all required preventive maintenance procedures 

including intervals) 

• Repair (descriptions of all recommended repair procedures including spare parts) 

• Additional procedures, if any (calibration, decommissioning) 

Product manual, reference information 

• Reference information (article numbers for documentation referred to in Product 

manual, procedures, lists of tools, safety standards) 

• Part list 

• Foldouts or exploded views 

• Circuit diagrams 




RobotWare manuals 

The following manuals describe the robot software in general and contain relevant reference 

information: 

• RAPID Overview: An overview of the RAPID programming language. 

• RAPID reference manual part 1: Description of all RAPID instructions. 

• RAPID reference manual part 2: Description of all RAPID functions and data types. 

• Technical reference manual - System parameters: Description of system 

parameters and configuration workflows. 

Application manuals 

Specific applications (e.g. software or hardware options) are described in Application 

manuals. An application manual can describe one or several applications. 

An application manual generally contains information about: 

• The purpose of the application (what it does and when it is useful) 

• What is included (e.g. cables, I/O boards, RAPID instructions, system parameters) 

• How to use the application 

• Examples of how to use the application 

Operator’s manuals 

This group of manuals is aimed at those having first hand operational contact with the robot, 

i.e. production cell operators, programmers and trouble shooters. The group of manuals 

include: 

• Operator’s manual - IRC5 with FlexPendant 

• Operator’s manual - RobotStudioOnline 

• Trouble shooting Manual for the controller and robot 

Miscellaneous 

A number of manuals provide generic descriptions of the robot and robot system. These 

include: 

• Robot fundamentals (describing the fundamental aspects, functions, concept and 

similar, of a robot system to provide a basic understanding of the robot system) 





Index 

B 

Boot application 20 

C 

Calibration position 26 

Connecting a PC 15 

control tools, overview 47 

Controller, connect to RobotStudioOnline 17 

Controller, Restart 31 

C-start, Restart Controller 31 

E 

Ethernet 15 

F 

FlexPendant 10, 39 

FlexPendant main parts 39 

FlexPendant screen 41 

FlexPendant, connecting 9 

FlexPendant, hardware buttons 41 

I 

Install system 21 

Installation, RobotStudioOnline 12 

I-start, Restart Controller 31 

L 

License Key, Request 13 

Licnese Key, Install 13 

M 

Media Pool, about 46 

Media Pool, Install 11 

N 

network 15 

P 

Program execution start button 41 

Proigram execution stop button 41 

R 

Restart system 23 

Robot, connect to RobotStudioOnline 17 

RobotStudioOnline, connect to controller 17 

RobotWare, about the media pool 46 

RobotWare, Install Media Pool 11 

RUN button 41 

S 

Select system 23 

Service port 15 

service port 15 

Set network connections 22 

Start and select system 19 

Start without system software 20 

STOP button 41 

T 

Teach pendant unit 39 

tool, overview control tools 47 

TPU 39 

W 

Warm start, Restart Controller 31 

X 

X-start 19 

X-start, Restart Controller 31

3HAC021564-001_rev A_en.pdf - Technology

Transform your PDFs into Flipbooks and boost your revenue!

Delete template?

Save as template ?