ABB IRC5 Compact User manual

© Copyright 2006 ABB. All rights reserved.
Operating manual
Getting started, IRC5 and RobotStudio
Document ID: 3HAC 027097-001
Revision: B

© Copyright 2006 ABB. All rights reserved.
The information in this manual is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed asany kind of guarantee or warranty by ABB forlosses, damages topersons
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 2007 ABB All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden

Table of Contents
33HAC 027097-001 Revision: B
© Copyright 2006 ABB. All rights reserved.
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1 Procedures 7
1.1 Procedure for single robot systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Procedure for MultiMove systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Common procedures for all systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 General 17
2.1 What you need to get the system started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 What is a FlexPendant? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 What is RobotStudio?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.4 What is RobotWare?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.5 About the media pool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.6 When to use the FlexPendant and RobotStudio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.7 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Table of Contents
43HAC 027097-001 Revision: B
© Copyright 2006 ABB. All rights reserved.

Overview
53HAC 027097-001 Revision: B
© Copyright 2006 ABB. All rights reserved.
Overview
About this manual This manual is to be used when starting up the system for the very first time. It contains
excerpts from other documents included in the robot system delivery.
Usage This manual contains instructions for starting up the IRC5 robot controller for the very first
time after the physical installation has been completed.
Who should read this manual?
This manual is intended for:
•Commissioning personnel
Prerequisites The reader should be familiar with:
•Mechanically installing the robot hardware.
•Be trained in robot operation.
The contents of the manual assumes all hardware (manipulator, controller and such) has been
installed correctly and connected to each other.
Organization of chapters
The manual is organized in the following chapters:
References
Revisions
Chapter Contents
1. Procedures Procedures for setup and startup of the IRC5 robot system.
2. General Descriptions of the parts in IRC5 robot system.
Reference Document Id
Product manual - IRC5 3HAC021313-001
Operating manual - IRC5 with FlexPendant 3HAC16590-1
Operating manual - RobotStudio 3HAC032104-001
Operating manual - Trouble shooting 3HAC020738-001
Technical reference manual - System parameters 3HAC17076-1
Application manual - MultiMove 3HAC021272-001
Revision Description
-Replaces manual with document id 3HAC 021564-001.
Released with RobotWare 5.08.
APolish translation added.
BRobotStudio Online is integrated in RobotStudio. Title adjusted.

Safety note
3HAC 027097-001 Revision: B6
© Copyright 2006 ABB. All rights reserved.
Safety note
Overview Please note that there is no information regarding safety aspects in this manual!
In an effort to keep this manual short, there is no information regarding:
•safe handling and operation of the equipment
•generic reference information
•detailed procedures
This information can be found in the Product manuals or the Operating manuals delivered
with the robot system.

1 Procedures
1.1. Procedure for single robot systems
73HAC 027097-001 Revision: B
© Copyright 2006 ABB. All rights reserved.
1 Procedures
1.1. Procedure for single robot systems
Overview This instruction is valid for IRC5 single robot systems.
A single robot system contains either a Single Cabinet Controller (controller with integrated
Control Module and Drive Module) ora Dual Controller (Control Module to which one Drive
Module is connected).
How to get started This procedure details how to get started with a single robot system.
Action Info/illustration
1. Mechanically install the robot and controller, and
connect the electrical power and signal cables
between them. Also connect the electrical power
supply.
These procedures are detailed in
the Product Manuals of robot and
controller respectively.
2. Make sure all safety related connections are made
correctly. Refer to the work station wiring diagram.
3. Connect the FlexPendant to the controller.
xx0500001854
A: FlexPendant connector, Single
Cabinet Controller
4. If the robot system is delivered with fully functional
system software installed, you can proceed as
detailed in section How to switch on power in
Common procedures for all systems on page 11.
If no functional system software has been installed,
please proceed as detailed in section Common
procedures for all systems on page 11.
A

1 Procedures
1.2. Procedure for MultiMove systems
3HAC 027097-001 Revision: B8
© Copyright 2006 ABB. All rights reserved.
1.2. Procedure for MultiMove systems
Overview This instruction is valid for IRC5 multi robot systems, that is, systems using the MultiMove
option.
xx0400001042
A MultiMove robot system contains either a Single Cabinet Controller (an integrated Control
Module and Drive Module as shown in the illustration above) or a separate Control Module
to which a number of Drive Modules (one for each robot being run by the system) have been
connected. Up to four robots may be operated by a MultiMove system.
NOTE!
All multi robot systems are configured as single robot systems on delivery. In order to be fully
functional as multi robot systems, these systems must be re-configured.
How to perform this is detailed in Operating manual - RobotStudio.
How to get started This procedure details how to get started with a multi robot system.
Action Info
1. Mechanically install the robot and
controller,and connecttheelectrical power
and signal cables between them. Also
connect the electrical power supply.
These procedures are detailed in the
Product Manuals of robot and controller
respectively.
Continues on next page

1 Procedures
1.2. Procedure for MultiMove systems
93HAC 027097-001 Revision: B
© Copyright 2006 ABB. All rights reserved.
2. Connect the Ethernet cables from each
Drive Module to the Control Module
Ethernet card.
Make sure the Drive Modules are
connected in the correct order! The order
must correspond to the order in which the
key strings are entered when creating the
system.
xx0400001141
Connections:
• A: Robot communication card
• B: Ethernet card
• C: Ethernet connection to Drive
Module #1 (connected on delivery)
• D: Ethernet connection to Drive
Module #2
• E: Ethernet connection to Drive
Module #3
• F: Ethernet connection to Drive
Module #4
3. Before connectingthesafety signalcables,
remove jumpers from connectors X7, X8,
X14 and X17 asrequired by the number of
Drive Modules to connect.
Connectthesafetysignalcablesfromeach
Drive Module to the Control Module panel
board as shown in the figure.
xx0400001295
Connections:
• X7: safety signal cable to Drive
Module #1(connected on delivery)
• X8: safety signal cable to Drive
Module #2
• X14: safety signal cable to Drive
Module #3
• X17: safety signal cable to Drive
Module #4
Action Info
Continued
Continues on next page

1 Procedures
1.2. Procedure for MultiMove systems
3HAC 027097-001 Revision: B10
© Copyright 2006 ABB. All rights reserved.
4. Make sure all safety related connections
are made correctly. Refer to the work station wiring diagram.
5. Connect the FlexPendant to the controller.
xx0500001854
A: FlexPendant connector, Single Cabinet
Controller
6. Proceed as detailed in section Common
procedures for all systems on page 11.
Action Info
A
Continued