1 Calibration - Technology

Calibration Pendulum Instruction 

Calibration equipment 

S4Cplus/IRC5

Calibration Pendulum Instruction 

Document ID: 3HAC 16578-1 

Revision: C

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 2003 ABB All rights reserved. 

ABB Automation Technologies AB 

Robotics 

SE-721 68 Västerås 

Sweden

Table of Contents 

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 

1 Calibration 5 

1.1 To what robots does this apply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 

1.2 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 

1.2.1 Types of calibration procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 

1.2.2 Storage and startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 

1.2.3 Setting of Levelmeter 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 

1.2.4 Calibration of Pendulum sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 

1.2.5 Checking of individual sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 

1.2.6 How to calibrate the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 

1.2.7 Calibration pendulum kit, contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 

1.3 Preliminaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 

1.3.1 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 

1.3.2 Updating revolution counters with TPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 

1.3.3 Updating revolution counters with FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 

1.3.4 Calibration Pendulum II procedure on TPU, S4Cplus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 

1.3.5 Calibration Pendulum II procedure on FlexPendant, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 

1.3.6 Initialization of calibration pendulum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 

1.4 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 

1.4.1 Reference positioning Calibration Pendulum II for axis 1 (general) . . . . . . . . . . . . . . . . . . . . . . . 31 

1.4.2 Calibration sensor mounting positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 

1.4.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 

1.4.4 Calibration, all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 

1.5 After calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 

1.5.1 Post calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 

3HAC 16578-1 

Rev.C 3

Overview 

Overview 

About This 

Manual 

This information product is a manual containing instructions for calibrating a robot, using the 

calibration pendulum method. 

Usage 

This manual should be used during calibration with the pendulum method using the 

Calibration Pendulum 3HAC 15716-1. 

Who Should Read 

This Manual 

This manual is intended for: 

• installation personnel on the installation site. 

• repairing personnel during repair or maintenace. 

Prerequisites 

The reader should have... 

• the required knowledge of how the robot works 

• a basic understanding of what calibration does and how it is performed. 

Organization of 

Chapters 

The manual is organized in the following chapters: 

Chapter 

Contents 

1. Calibration 

Revisions 

Revision 

Description 

0 First edition 

A 

B 

C 

Information on IRB 7600/2.3/500 added 

Paths to calibration software revised 

Minor editorial changes 

Minor editorial changes 

Methods to calibrate the pendel tool added 

Changes in Information about IRB 7600/2.3/500 

Pendellum Calib II intrud. 

Methods to calibrate the pendel tool added for IRC5 

Changes in Information about IRB 7600/2.3/500 

4 

Rev.C 3HAC 16578-1

1 Calibration 

1.1. To what robots does this apply 


1.1. To what robots does this apply 

Serial numbers 

Robots, in general, may be calibrated using a number of methods. This manual describes 

robot calibration using the Calibration Pendulum method, which is applicable to the 

following ABB robots: 

Robot model 

Serial number 

IRB 140 14M-21493 

IRB 1400 14-26001 

IRB 2400 

M2000 

IRB 4400 

M2000 

IRB 6600 

IRB 7600 

IRC5 

24-23050 and on. 

Robots with serial numbers 24-23051, 24-23052, 24-23054, 24-23055, 

24-23056 and 24-23061 were not calibrated using the calibrations 

pendulum method before delivery from ABB, but these robots are fully 

compatible with this method. 

44-21782 and on. 

All robots 

76-20187 and on. 

NOTE! Robots 76-20190 and 76-20191 are excluded! 

All robots using IRC5 

3HAC 16578-1 

Rev.C 5


1.2.1. Types of calibration procedures 

1.2 General 

1.2.1. Types of calibration procedures 

When to calibrate 

The system must be calibrated if one or more of the listed failure below occurs. 

Changed resolver 

values 

Calibrate the measurement system carefully as detailed in section Calibration if any of the 

resolver values has been changed. This may occur when parts affecting the calibration 

position have been replaced on the robot. 

Contents of the 

revolution counter 

memory are lost 

Calibrate the system roughly as detailed in section Updating revolution counters with TPU 

on page 21if the contents of the revolution counter memory are lost. This may occur when: 

• the battery has been discharged 

• a resolver error occurs 

• the signal between a resolver and measurement board interrupted 

• a robot axis has been moved while the control system was disconnected 

6 

Rev.C 3HAC 16578-1


1.2.2. Storage and startup 

1.2.2. Storage and startup 

NOTE! 

Always store the pendulum sensor in its carrying bag laying down or mounted on the tool 

plate in a horizontal position. 

Storage in a non horizontal position may cause long term drift and errors in the Wyler 

sensors. 

Storage 

After storage the pendulum tool must be mounted in a horizontal position and be warmed up 

(power on) for at least 5 minutes before use. 

Storage position or warm up position illustrated below 

A 

B 

xx0300000152 

A Calibration Pendulum 3HAC 4540-1 

B Calibration plate 3HAC 020552-002 

3HAC 16578-1 

Rev.C 7


1.2.3. Setting of Levelmeter 2000 

1.2.3. Setting of Levelmeter 2000 

Levelmeter 2000 

If the Calibration Pendulum is turned off, it must be warmed up for at least 5 minutes before 

use. 

The Levelmeter 2000 should be set to measure the angle (DEG°) with a sensibility of tree 

decimals, ex. 0,330° 

- 

+ 

Port/Sensor 

A 

50 

BATT 

0000000 00000 

°oo A°oo mRAD mm/m DEG 

GON "1/12" "1/10" "/REL" mm/REL 

LEVELMETER 2000 

+ 

ON/MODE 

ZER O S E LE CT 

- 

ENTER 

HOLD 

S END/ESC 

W YL ER 

A B OUT 

xx0300000156 

8 

Rev.C 3HAC 16578-1


1.2.4. Calibration of Pendulum sensors 


Location of 

sensors 

The illustration shows how to locate the sensors and how to connect them to the Levelmeter 

2000. 

xx0300000157 

A Connect sensor F 

B Connect sensor G 

C Connection controller SIO 1 

D Selection pointer 

E Measuring pointer 

F Sensor A 

G Sensor B 

Required 

equipment 

Equipment, etc. 

Spare part 

no. 

Art. no. 

Note 

Calibration plate 3HAC 020552-002 

Calibration pendulum kit 3HAC 15716-1 Described in section 

Calibration pendulum kit, 

contents on page 16 

Isopropanol 11771012-208 For cleaning the sensor 

attachment points 

3HAC 16578-1 

Rev.C 9



Calibration tool 

A 

B 

xx0300000152 

A 

B 

Calibration Pendulum 

Calibration plate 

The procedure below details how to calibrate the sensors to the Levelmeter 2000. 

Step Action Info/Illustration 

1. Place the calibration plate on a 

steady and flat surface. Clean the 

calibration plate surface with 

isopropanol. 

Clean the surface of the Calibration 

Pendulums tree contact surfaces 

with isopropanol. 

Fit the pendulum tool in one of the 

two possible positions. 

2. Press repeatedly the button ON/ 

MODE until the marker moves to the 

text SENSOR. 

3. Press repeatedly the button ENTER. 

4. Press repeatedly the button ZERO/ 

SELECT until“ A” appears under the 

Port/Sensor. 

5. Press the button ENTER - wait until 

“A” stops flashing. 

6. Press the button ON/MODE until the 

marker moves to the text “ZERO”. 

7. Press the button ENTER - The 

direction indicator (+/-) and the last 

zero-offset will be displayed. Wait a 

couple of seconds for the sensors to 

stabilize. 

shown in illustration Location of sensors on 

page 9 

10 

Rev.C 3HAC 16578-1




8. Press the button HOLD - wait until 

the marker under ZERO starts to 

blink. 

9. Remove the pendelum tool, turn it 

180° and fit the tool in the 

corresponding hole pattern.NOTE! 

Do not change the position of the 

calibration plate.- wait a couple of 

seconds for the sensors to stabilize.. 

xx0300000207 

10. Press the button HOLD -and wait a 

couple of seconds. The new zerooffset 

will be displayed.. 

11. Press the button ENTER, now the 

sensor is calibrated and should 

display the same value, but with 

different direction (+/-) for the two 

positions. 

12. Adjust the instrument as described in 

step 2- 5, to read the sensor ”B”. 

13. Repeat the actions described in step 

6 - 11 

14. Adjust the instrument as described in 

step 2- 5, to read the sensor “AB”. 

15. Check the results. Shown in chapter Checking of individual 

sensors on page 12. 

3HAC 16578-1 

Rev.C 11


1.2.5. Checking of individual sensors 


Calibration tool 

A 

B 

xx0300000152 

A 

B 

Calibration pendulum 

Calibration plate 

Required 

equipment 

Equipment, etc. Spare part no. Art. no. Note 

Calibration pendulum 

kit 

3HAC 15716-1 

Contains all hardware 

required for calibration, 

specified inCalibration 

pendulum kit, contents 

Calibration plate 3HAC 020552-002 

Isopropanol 11771012-208 For cleaning the sensor 

attachment points 

Checkl 

The procedure below details how to check isopropanolindividual sensors in the Levelmeter 

2000. 

12 

Rev.C 3HAC 16578-1




1. Place the calibration plate on a steady 

and flat ground, Clean the surface of 

the calibration plate with isopropanol. 

Clean the surface of the Calibration 

Pendulums contact surfaces with 

isopropanol. 

Fit the Calibration Pendulum tool in 

one of the two possible positions. 

2. Adjust the instrument to read the 

sensor “A” and “B”. 

3. Wait a couple of seconds for the 

sensors to stabiliz, read the value 

shown by the instrument. 

4. Remove the Calibration Pendulum 

tool, turn it 180° and refit it in the 

corresponding hole pattern. wait a 

couple of seconds until the sensors 

have been stabilized. 

NOTE! Do not change the position 

of the calibration plate. 

If the instrument read anything else, 

adjusts it. As described in step 2- 5, 

Calibration of sensors . 

180 

A 

B 

5. Read the values for “A” and “B” shown 

by the instrument. The difference 

between the two readings should be 

less than 0,002° deg. and have 

opposite directions (+/-). If the 

difference is greater, the sensor must 

be recalibrated. 

C 

xx0300000261 

Described in step 1-15 inCalibration of 

sensors . 

D 

3HAC 16578-1 

Rev.C 13


1.2.6. How to calibrate the robot system 


General 

This section provides an overview of the procedure required when calibrating the robot 

system. Many of the steps in the procedure are detailed in other sections to which references 

are given. 

Procedure 

NOTE! 

Before use of the Pendulum Calibration all external axis ( 7 --->) must be disconnected. 

Before use of the Pendulum Calibration, clean all the mounting surfaces for the sensors 

on the robot. 

Step Action Illustration 

1. Install the robot. Detailed in the "Installation 

Manual". 

2. Check that all required hardware is available for 

calibrating the robot. 

3. Remove all the covers for the calibration tool 

sensorsmounting surfaces. 

Required hardware is 

specified in the calibrating 

procedures for each axis. 

Use standard tools 

4. Clean the guide pin holes. Use isopropanol. 

5. Connect the calibration equipment to the robot 

controller and initialize it. 

6. Manually, run the robot axes to be calibrated to a 

position close to the correct calibration position. 

Specified in Initialization of 

calibration pendulum on 

page 29. 

Use the calibration scales 

fitted to each robot axis to 

locate this position. 

7. Start the calibration program. Detailed in Calibration 

Pendulum II procedure on 

TPU, S4Cplus on page 26. 

8. Calibrate each axis in sequence as detailed in the 

program. 

9. Verify that the calibration was successfully carried 

out. 

Detailed in each axis' 

calibration instruction. 

Detailed in Post calibration 

procedure on page 52. 

General - 

Calibration 

Pendulum 

In the calibration procedure the position of the sensor is first measured at the reference plane. 

Then the pendulum calibration sensor is placed on each axis and the robot is run to its 

calibration position, thus reducing the sensor difference to close to zero. 

All article numbers of relevant equipment are specified in their instructions respectively. 

Peripheral 

equipment 

The robots upper arm must be free from any peripheral equipment during calibration. Fitted 

tools and similar will cause erroneous calibration positions. 

14 

Rev.C 3HAC 16578-1



Calibration order The axes must be adjusted in increasing sequence, i.e. 1 - 2 - 3 - 4 - 5 - 6. 

Location of 

sensors 

The positions where the calibration sensor and reference sensor should be fitted during 

calibration, are specified in Calibration sensor mounting positions on page 32. 

3HAC 16578-1 

Rev.C 15


1.2.7. Calibration pendulum kit, contents 


General 

The calibration pendulum kit contains all required hardware to calibrate all robot models 

(except IRB 6400R) using the calibration pendulum method. 

These kits may only be rented from ABB at this time, please contact the Service Department. 

Contents of 

calibration 

pendulum kit 

3HAC 15716-1 

Qty Contents Art. no. Rem. 

2 Inclinometer, Wyler 3HAC 12837-7 

Zerotronic 

1 Cable set Wyler 3HAC 15144-1 All required cables 

1 Leveltronic NT/41 3HAC 15732-1 

1 Calibration pendulum 3HAC 4540-1 

1 Turning disk adapter 3HAC 16423-1 May be turned both 

ways to fit IRB 140, 

IRB 1400, IRB 2400 

and IRB 4400. 

Includes all guide 

pins and attachment 

screws. 

Also see illustration 

below! 

4 Batteries For battery supply of 

"Leveltronic NT/41" 

1 Thread tap, M8 For repairing any 

damaged protective 

cover attachment 

holes 

5 Protective covers and 

attachment screws 

For replacing any 

damaged protective 

covers 

1 Location pin 3HAC 14137-1 58 mm long 

For IRB 6600 and IRB 

7600, axis 1 

1 Location pin 3HAC 14137-2 68 mm long 

For IRB 140, IRB 

1400, IRB 2400 and 

IRB 4400, axis 1 

1 User documentation 3HAC 16578 

Illustration, turning 

disk adapter 

May be turned both ways to fit IRB 140, IRB 1400, IRB 2400 and IRB 4400. 

16 

Rev.C 3HAC 16578-1



xx0200000276 

A 

B 

C 

D 

Guide pin, 8 mm 

Guide pin, 6 mm 

Screw, M10 

Screw, M6 

3HAC 16578-1 

Rev.C 17


1.3.1. Checking the calibration position 

1.3 Preliminaries 


General 

Check the calibration position before beginning any programming of the robot system. This 

may be done in one of two ways: 

• Using a MoveAbsJ instruction with argument zero on all axes 

• Using the Jogging window on the teach pendant 

Using a 

MoveAbsJ 

instruction on the 

TPU, S4Cplus 

This section describes how to create a program, which runs all the robot axes to their zero 

position 

Step Action Note 

1. Crate a new program 

2. Use MoveAbsJ 

3. Create the following program: MoveAbsJ 

[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOffs 

, v1000, z50, Tool0 

4. Run the program in manual mode 

5. Check that the calibration marks for the axes align 

correctly. If they do not, update the revolution 

counters! 

The calibration marks are 

shown in section Calibration 

scales and correct axis 

position on page 44. 

How to do this is detailed in 

section Updating revolution 

counters with TPU on page 

21 

18 

Rev.C 3HAC 16578-1



Using a 

MoveAbsJ 

instruction on the 

FlexPendant, 

IRC5 

This section describes how to create a program, which runs all the robot axes to their zero 

position. 


1. On ABB menu tap Program Editor. 

2. Create a new program. 

3. Use MoveAbsJ in the Motion&Proc menu. 

4. Create the following program: MoveAbsJ 

[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOff 

s, v1000, z50, Tool0 

5. Run the program in manual mode. 

6. Check that the calibration mark for the particular 

axis align correctly. If it does not, update the 

revolution counters! 





How to update the revolution 

counters is detailed in section 

Updating revolution counters 

with FlexPendant on page 24. 

Using the 

Jogging window 

on the TPU, 

S4Cplus 

This section describes how to jog the robot to all axes zero position. 

Step Action Illustration/information 

1. Open the Jogging window. 

2. Choose running axes-by-axes. 

xx0100000195 

3. Manually run the robot axes to a position where the 

resolver offset value read, is equal to zero. 



counters! 

xx0100000196 





Detailed in section Updating 

revolution counters with TPU 

on page 21. 

3HAC 16578-1 

Rev.C 19



Using the 

Jogging window 

on the 

Flexpendant, 

IRC5 

This section describes how to jog the robot to all axes zero position. 


1. Tap Jogging in the ABB menu 

2. Tap Motion mode to chose group of axes to jog 

3. Tap axes 1-3 to jog axes 1 ,2 or 3 

4. Manually run the robots axes to a position where the 

resolver offset value read, is equal to zero. 



counters! 





How to update the counters 

is detailed in section 

Updating revolution counters 

with FlexPendant on page 

24. 

20 

Rev.C 3HAC 16578-1


1.3.2. Updating revolution counters with TPU 


General 

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 TPU. 

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. 


1. Select axis-by-axis motion mode. 

2. Jog the robot so that the calibration marks lie within 

the tolerance zone. 

IRB 140, 1400, 2400, 4400: Axes 5 and 6 must be 

positioned together! 

3. Note! Axis 4 and 6 do not have any mechanical stops 

and there is a risk of positioning them with wrong 

revolution, even if the calibration marks lie correctly! 

Read more in Correct calibration position of axis 4 

and 6, below. 

4. When all axes are positioned, store the revolution 

counter settings as detailed in following procedure 

Storing the revolution counter setting. 

Shown in section Calibration 



Correct 

calibration 

position of axis 4 

and 6 

When running the robot to calibration position, it is extremely important to make sure that 

axes 4 and 6 of the below mentioned robots are positioned correctly. The axes do not have 

any mechanical stops and can therefor be calibrated at the wrong turn. 

Make sure the axes are positioned according to the correct calibration values, not only 

according to the calibration marks. The correct values are found on a label, located either on 

the lower arm or underneath the flange plate on the base. 

At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before 

the revolution counters has been updated. 

If one of the below mentioned robots are rotated one or more turns from its calibration 

position before updating the revolution counter, the exact calibration position will be lost due 

to uneven gear ratio. This affects the following robots: 

Robot variant Axis 4 Axis 6 

IRB 140 Yes Yes 

IRB 1400 Yes Yes 

IRB2400L (5kg) Yes No 

IRB6400 / 200kg Yes No 

IRB6400R / 200kg Yes No 

IRB6600 / 175kg_2,55 m Yes No 

3HAC 16578-1 

Rev.C 21



Robot variant Axis 4 Axis 6 

IRB6600 / others Yes Yes 

IRB7600 Yes Yes 

Storing the 

revolution 

counter setting 

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

revolution counter setting. 


1. Press the button "Miscellaneous" then ENTER to select the 

service window. 

xx0100000194 

2. Select Calibration from the View menu. 

The Calibration window appears. 

If there is more than one unit connected to the robot, they will 

be listed in the window. 

xx0100000201 

3. Select the desired unit and choose Rev Counter Update 

from the Calib menu. 

The Revolution Counter Update window appears. 

xx0100000202 

22 

Rev.C 3HAC 16578-1




4. Select the desired axis and press Incl to include it (it will 

be marked with an x) or press All to select all axes. 

5. Press OK when all axes that are to be updated are marked 

with an x. 

CANCEL returns to the Calibration window. 

6. Press OK again to confirm and start the update. 

CANCEL returns to the Revolution Counter Update window. 

7. At this point, it is recommended that the revolution counter 

values are saved to a diskette. 

8. 

Not required. 

- 

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. 

How to perform the check is detailed in section Checking the 

calibration position on page 18. 

3HAC 16578-1 

Rev.C 23


1.3.3. Updating revolution counters with FlexPendant 


General 

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. 

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. 


1. Select axis-by-axis motion mode. 

2. Jog the robot so that the calibration marks lie within 

the tolerance zone. 

IRB 140, 1400, 2400, 4400: Axes 5 and 6 must be 

positioned together! 

3. Note! Axis 4 and 6 do not have any mechanical stops 

and there is a risk of positioning them with wrong 

revolution, even if the calibration marks lie correctly! 

Read more in Correct calibration position of axis 4 

and 6, below. 

4. When all axes are positioned, store the revolution 

counter settings as detailed in following procedure 

Storing the revolution counter setting. 




Correct 

calibration 

position of axis 4 

and 6 

When running the robot to calibration position, it is extremely important to make sure that 

axes 4 and 6 of the below mentioned robots are positioned correctly. The axes do not have 

any mechanical stops and can therefor be calibrated at the wrong turn. 

Make sure the axes are positioned according to the correct calibration values, not only 

according to the calibration marks. The correct values are found on a label, located either on 

the lower arm or underneath the flange plate on the base. 

At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before 

the revolution counters has been updated. 

If one of the below mentioned robots are rotated one or more turns from its calibration 

position before updating the revolution counter, the exact calibration position will be lost due 

to uneven gear ratio. This affects the following robots: 

24 

Rev.C 3HAC 16578-1



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. 

en0400000771 

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. 

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 on page 18. 

3HAC 16578-1 

Rev.C 25


1.3.4. Calibration Pendulum II procedure on TPU, S4Cplus 


General 

This section details how to use the Teach Pendant Unit (TPU) when calibrating the robot 

using the calibration pendulum method. 

Procedure 


1. Press the 

"Program" button 

on the TPU. 

2. Select "Special", 

and then "Call 

service routine". 

3. Start the program: 

"Calpendulum.rutin 

". 

4. Select the required 

calibration 

procedure and 

press "START". 

xx0300000009 

xx0200000188 

26 

Rev.C 3HAC 16578-1




5. Enter the value of 

your choice, of 

which robot axes to 

be calibrated. 

Press OK . 

6. Press "0" to 

acknowledge the 

selection made. 

Press OK . 

7. Proceed to 

calibrate the 

individual robot 

axes. 

xx0200000190 

Default value: All axes 

In this example, axis 1 was selected. 

Detailed in the calibration instructions for the robot axes. 

3HAC 16578-1 

Rev.C 27


1.3.5. Calibration Pendulum II procedure on FlexPendant, IRC5 

1.3.5. Calibration Pendulum II procedure on FlexPendant, IRC5 

Overview 

This section details how to use the FlexPendant when calibrating the robot using the 

Calibration pendulum method 

Procedure 


1. On the ABB menu tap Program Editor 

2. Tap on routines 

3. Select the Calpendulum routine 

4. Start the program by pressing “START” 

5. Selection of Production or Field Service Calibration Select Field Service 

Calibration, Production is 

only used in ABB:s prodution 

plant 

6. Selection of alternativ positions for axes 3-6. Used if you want to calibrate 

axes 1-2, with axes 3-6 in an 

alternativ position. Look at 

sectionAlternative 

calibration positionsor 

section Alternative 

calibrating 

7. Follow the futher istructions on the FlexPendant Proceed to calibrate the 

individual robot axes, 

detailed in section 

Calibration sensor mounting 

positions on page 32 

28 

Rev.C 3HAC 16578-1


1.3.6. Initialization of calibration pendulum 


General 

Whenever calibration pendulum is used for calibrating the robot, the equipment must first be 

initialized as detailed below. 

The Levelmeter 2000 is shown for reference below: 

E 

D 

xx0200000126 

A B C 

A Connection sensor A 

B Connection sensor B 

C Controller connection SIO 1 

D Selection pointer 

E Measuring unit 

Overview 

Shown below is an outline of how to initialize the Levelmeter 2000. Detailed procedures are 

specified in the manual supplied by the manufacturer. 


1. Make sure the Levelmeter 2000 has reached normal 

operating temperature before connecting it to 

anything. 

Also switch the power on for a couple of minutes 

before operating the unit. 

2. Connect the Levelmeter 2000 to the COM2 port in the 

control cabinet through the connector marked OUT . 

Shown in the figure in 

section General on page 29. 

3HAC 16578-1 

Rev.C 29




3. Connect sensors A and B. Detailed in Connection of 

sensors on page 30. 

4. Calibrate the robot! 

Address 


1. Make sure the sensors have different addresses. Any 

addresses will do, as long as they differ from each 

other. 

Detailed in the 

documentation supplied by 

sensor manufacturer. 

Found in the calibration kit 

box. 

Connection of 

sensors 


1. Connect the sensor to the Sensor connection points. Marked A and B . 

Shown in the figure in 

section General on page 29. 

2. Press ON/MODE . 

3. Press ON/MODE until the dot flashes under 

SENSOR . 

4. Press ENTER. 

5. Press ZERO/SELECT arrows until a flashing "A B" 

is shown. 


Wait until the "A B" flashes again. 


Result 

The Levelmeter 2000 is now initialized and ready for service. 

30 

Rev.C 3HAC 16578-1


1.4.1. Reference positioning Calibration Pendulum II for axis 1 (general) 

1.4 Calibration 

1.4.1. Reference positioning Calibration Pendulum II for axis 1 (general) 

Overview 

This section specifies the handling of the Calibration Pendulum in reference position for axis 

1 on all robots. 

Reference 

positioning 

This section details the procedure for preparation of the calibration pendulum before 

calibration of axis 1. 


1. Compress the spring 

by moving the inner 

hand wheel (axial 

movement) 

A 

2. Rotate the inner 

hand wheel 

clockwise on the 

shaft to lock the 

spring in compressed 

position. 

xx0400001101 

B 

3. After calibration of 

axis 1 

xx0400001102 

Release the compressed spring 

3HAC 16578-1 

Rev.C 31


1.4.2. Calibration sensor mounting positions 


Introduction 

This section specifies the mounting positions and directions of all calibration sensors on all 

robot systems using the Calibration Pendulum method. 

NOTE! Make sure that the cabling does not affect the Calibration Pendulum position. 

NOTE! If position breaker(s) are fitted for axis 1, they must be removed before use of 

the Calibration Pendulum on the reference position. 

Additional information on calibration, alternative calibration positions etc, may be found in 

the Repair Manual. 

NOTE! After calibration of axis 1, release the compressed spring on the pendulum 

calibration tool. 

Further instructions about reference calibration of axis 1 are given in section Reference 

positioning Calibration Pendulum for axis 1 (general) 

IRB 140 

The illustrations below show the mounting positions and directions for both the reference 

sensor and axis sensors on the robot 

Reference position 

IRB 140 

xx0200000244 

A 

Calibration pendulum in reference sensor position. NOTE! The pendulum is only fitted 

in one position at a time! 

32 

Rev.C 3HAC 16578-1



Axis 1 IRB 140 

\xx0200000245 

A 

B 

C 

Calibration sensor, axis 1. NOTE! The pendulum is only fitted in one position at a 

time! 

Locating pin 

Calibration pendulum attachment screw 


xx0200000246 

A 

Calibration sensor, axis 2. NOTE! The pendulum is only fitted in one position at a time! 

3HAC 16578-1 

Rev.C 33



Axis 3, 4, 5 and 6 

IRB 140 

xx0200000266 

A Calibration sensor, axis 3 

B Turning disk adapter 

C Sensor locking screw 

D Sensor cable, sensor B 

E Sensor cable, sensor A 

IRB 1400 



34 

Rev.C 3HAC 16578-1




IRB 1400 

xx0200000248 

A 

Calibration pendulum in reference sensor position. NOTE! The pendulum is only 

fitted in one position at a time! 


xx0200000249 

A 

B 

C 

Calibration sensor, axis 1. NOTE! The pendulum is only fitted in one position at a time! 

Locating pin 


3HAC 16578-1 

Rev.C 35




xx0200000281 

A 


time! 

Axis 3, 4, 5 and 6 

IRB 1400 

xx0200000266 




D Sensor cable, sensor B 

E Sensor cable, sensor A 

36 

Rev.C 3HAC 16578-1



IRB 2400 




IRB 2400 

xx0200000250 

A 




xx0200000251 

A 

B 

C 


time! 

Locating pin 


3HAC 16578-1 

Rev.C 37




xx0200000280 

A 


time! 

Axis 3, 4, 5 and 6 

IRB 2400 

xx0200000266 




38 

Rev.C 3HAC 16578-1



D 

E 

Sensor cable, sensor B 

Sensor cable, sensor A 

IRB 4400 




IRB 4400 

xx0200000252 

A 




xx0200000253 

A 

B 

C 


time! 

Locating pin 


3HAC 16578-1 

Rev.C 39




xx0200000279 

A 


time! 

Axis 3, 4, 5 and 6 

IRB 4400 

xx0200000266 

IRB 6600/7600 



40 

Rev.C 3HAC 16578-1




IRB 6600, IRB 

7600 

xx0200000183 

A 



Axis 1 IRB 6600, 

IRB 7600 

NOTE! If an old synchronization plate for axis 1 is mounted it is vital to change it to the 

new synchronization plate 3HAC 021287-001. 

xx0400001107 

NOTE! If position breaker(s) are mounted for axis 1, they must be dismounted before 

use of the Calibration Pendulum 3HAC 4540-1 on axis 1. 

3HAC 16578-1 

Rev.C 41



xx0200000177 

A 

B 

C 

Calibration pendulum. NOTE! The pendulum is only fitted in one position at a time! 


Locating pin 

Axis 2 IRB 6600, 

IRB 7600 

xx0200000178 

A Calibration pendulum, axis 2 

42 

Rev.C 3HAC 16578-1



Axis 3-6 IRB 6600, 

IRB 7600 

xx0300000274 

A B C 

A Fit the Calibration Pendulum, screw home the attachment screw (by hand) 

B Compress the spring and rotate the Calibration Pendulum counter clockwise 

C At the end of the counter clockwise movement drop the Calibration Pendulum into its 

calibration position 

NOTE! To ensure the result of the procedure to be accurate it is vital that it is performed 

identically each time. 

3HAC 16578-1 

Rev.C 43


1.4.3. Calibration scales and correct axis position 


Introduction 

This section specifies the calibration scale positions and/or correct axis position for all robot 

models. 


scales, IRB 140 

The illustration below shows the calibration scale positions on IRB 140: 

xx0200000157 

44 

Rev.C 3HAC 16578-1






en0200000272 




3HAC 16578-1 

Rev.C 45



en0200000273 



The illustration below shows the calibration scale positions on IRB 4400. 

The calibration marks for axes 2, 3, 4 and 5 are marked using punch mark tools. 

46 

Rev.C 3HAC 16578-1



xx0300000209 

A Punch, axis 2, 3HAB 1521-1 

B Punch, axis 3, 3HAB 1522-1 

C Punch, axis 4, 3HAB 1523-1 (there are two different versions of the marks,as shown 

in the figure) 

D Punch, axis 5, 3HAB 1524-1 

E Axes 5 and 6, IRB 4400/L10 

3HAC 16578-1 

Rev.C 47




scales, IRB 6600, 

IRB 6650, IRB 

6650S,IRB 7600 

The illustration below shows the calibration scales and their positions on the robot. 

The figure shows IRB 6600, but the scales and their positions are the same for IRB 6650S 

and IRB 7600. 

F 

E 

A1 

A2 

xx0200000176 

A1 Sync scale, axis 1(early design) 

A2 Sync scale, axis 1(new design) 

B Sync scale, axis 2 

C Sync scale, axis 3 

D Sync scale, axis 4 

E Sync scale, axis 5 

F Sync scale, axis 6 

48 

Rev.C 3HAC 16578-1


1.4.4. Calibration, all axes 


General 

This section is valid for all robot models using the calibration pendulum procedure except 

IRB 6400R. 

It details how to perform the actual fine calibration of each axis using special calibration 

equipment. The position to fit calibration sensors differ between different models and 

different axes. 

Equipment Article no. Note 

Calibration pendulum, 

complete set 

3HAC 15716-1 

Contains all hardware required for calibration of all 

robot versions except IRB 6400R. 

The contents are specified in Calibration pendulum 

kit, contents on page 16. 

Turning disk adapter 3HAC 16423-1 May be turned both ways to fit IRB 140, IRB 1400, 

IRB 2400 and IRB 4400. 

Included in the complete set. 

Isopropanol 1177 1012-208 For cleaning the sensor attachment points 

Sensor mounting 

positions 

The position of the calibration sensors are shown in Calibration sensor mounting positions 

on page 32. 

3HAC 16578-1 

Rev.C 49



Procedure 


1. Run the robot manually to the 

calibration position of the axis to be 

calibrated. 

2. Make a rough calibration. Detailed in Updating revolution counters with 

TPU on page 21. 

3. Turn the calibration equipment on, 

to allow it to reach operating 

temperature and stabilize for a 

couple of minutes. 

4. Remove any protective covers 

from the reference sensor, 

calibration sensor and locating pin 

attachment points. 

The same calibration pendulum is 

used as a "calibration sensor" and 

as a "reference sensor" depending 

on its function at the time. In the 

instruction below, the pendulum 

will be called "calibration sensor" or 

reference sensor" depending on 

the function. 

5. Clean the reference sensor, 

calibration sensor and locating pin 

attachment points with isopropanol 

. 

6. Valid for axis 1 only! 

Fit the locating pin to the 

manipulator base. 

Make sure the attachment surface 

is clean and free from any nicks or 

burrs. 

Art. no. specified in section General on page 

49. 

Shown in Calibration sensor mounting 

positions on page 32. 

50 

Rev.C 3HAC 16578-1




7. Connect the measurement cable 

from the calibration sensor to the 

Levelmeter 2000 unit. 

E 

D 

8. Start the calibration program from 

the TPU, and follow the instructions 

given, incl. fitting the calibration 

sensor when requested. 

NOTE! After fitting the sensor on 

the manipulator as specified on the 

TPU, clicking OK will start 

manipulator movement ! 

Make sure nobody is within the 

working range of the robot! 

9. Click OK . 

A number of menus will flash by 

briefly on the TPU, but no action is 

required on behalf of the operator 

until a specific action is displayed. 

10. Confirm the position of all 

calibrated axes when the 

calibration has been performed 

satisfactorily. 

11. Disconnect all calibration 

equipment and refit all protective 

covers. 

A B C 

xx0200000126 

• A: Connect sensor A here 

• B: Connect sensor B here 

• C: Connect SIO 1 in controller here 

• D: Measuring unit 

• E: Selection pointer 

The position to fit the reference sensor and 

calibration sensor respectively, are shown in 

Calibration sensor mounting positions on page 

32. 

NOTE that no additional tool is required for 

fitting the calibration pendulum for axes 1-3! 

Fitting the pendulum to the turning disk 

requires an adapter (included in the complete 

set). NOTE that there are two adapters! Article 

numbers, are specified in section General on 

page 49. 

How to handle the calibration program prior to 

the actual calibration of each axis is detailed in 

Calibration Pendulum II procedure on TPU, 

S4Cplus on page 26. 

Detailed in Post calibration procedure on page 

52. 

3HAC 16578-1 

Rev.C 51


1.5.1. Post calibration procedure 

1.5 After calibration 


General 

Perform the following procedure after calibrating any manipulator axis. The procedure is 

intended to verify that all calibration positions are correct. 

Procedure 


1. Run the calibration home position program twice. 

Do not change the position of the manipulator axes 

after running the program! 

2. Check the calibration positions. 

IRB 6600, IRB 6650, IRB 6650S and IRB 7600: 

Check the calibration positions of all axes. The 

acceptable tolerances are: 

• axis 2, 3: ±0.20 mm/m 

• axis 4, 5, 6: ±0.40 mm/m 

IRB 4400, IRB 6400R: Check the calibration positions 

of axes 6, 2 and 5. If axes 5 and 6 are within the 

tolerances given below, then axes 3 and 4 do not 

need to be checked. The acceptable accurancy is: 

• axes 2, 3: ±0.20 mm/m 

• axes 4, 5, 6: ±0.40 mm/m 

If the axes are outside the tolerance, start the 

calibration procedure from the beginning, in 

increasing sequence of the axes. 

3. Repeat the check as above. 

4. Adjust the calibration marks when the calibration is 

done. 

5. The system parameters will be saved to the storage 

memory at power off. 

6. Change the values on a new label and stick it on top 

of the label located 

• IRB 140, IRB 6600, IRB 6650, IRB 6650S, IRB 

7600, IRB 6400R: on the lower arm. 

• IRB 1400, IRB 2400, IRB 4400: underneath 

the flange plate on the base. 

7. Remove any calibration equipment from the 

manipulator. 

Detailed in section Checking 

the calibration position on 

page 18. 

Detailed in section 

Calibration scales and 

correct axis position on page 

44. 




52 

Rev.C 3HAC 16578-1

Index 

C 

Calibration position 21, 24 

Changed resolver values 6 

L 

Levelmeter 2000 connections 9 

Levelmeter 2000 instrument calibration 12 

Levelmeter 2000 settings 8 

R 

Reference positioning 31 

Revolution counters 21 

S 

Serial numbers 5 

Storage of the Wyler sensor 7 

U 

Updating counters 6 

Updating revolution counters 21 

3HAC 16578-1 

53



54 

Rev.C 3HAC 16578-1

3HAC 16578-1, rev.C, en 

 

ABB Automation Technology Products AB 

Robotics 

S-721 68 VÄSTERÅS 

SWEDEN 

Telephone: +46 (0) 21 344000 

Telefax: +46 (0) 21 132592

1 Calibration - Technology

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