ABB IRC5 Compact User manual

ABB Robotics
Operating manual
Trouble shooting, IRC5

© Copyright 2005-2010 ABB. All rights reserved.
Operating manual - Trouble shooting, IRC5
Robot Controller
IRC5
M2004
Document ID: 3HAC020738-001
Revision: K

© Copyright 2005-2010 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
construedasanykindofguarantee or warranty by ABB for losses, damagestopersons
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 2005-2010 ABB All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden

Table of Contents
33HAC020738-001 Revision: K
© Copyright 2005-2010 ABB. All rights reserved.
Overview of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Safety 7
1.1 Safety signals in the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Safety symbols on the manipulator labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Safety during trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Applicable safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Safe Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5.1 DANGER - Robot without axes' holding brakes are potentially lethal! . . . . . . . . . . . . . . . . . . . . 16
1.5.2 DANGER - Live voltage inside Drive Module!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.5.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
1.5.4 CAUTION - Hot parts may cause burns!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2 Trouble shooting Overview 23
2.1 Documentation and references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.3 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4 Tips and Tricks while trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4.1 Trouble shooting strategies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4.2 Work systematically. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4.3 Keeping track of history. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.5 Filing an error report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3 Troubleshooting by fault symptoms 33
3.1 Start-up failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2 Controller not responding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.3 Low Controller performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.4 All LEDs are OFF at Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.5 No voltage in service outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.6 Problem starting the FlexPendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.7 Problem connecting FlexPendant to the controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.8 Erratic event messages on FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.9 Problem jogging the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.10 Reflashing firmware failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.11 Inconsistent path accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.12 Oil and grease stains on motors and gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.13 Mechanical noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.14 Manipulator crashes on power down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.15 Problem releasing Robot brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.16 Intermittent errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4 Trouble shooting by Unit 55
4.1 Trouble shooting the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.2 Trouble shooting communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.3 Trouble shooting fieldbuses and I/O units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.4 Trouble shooting power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.4.1 Trouble shooting DSQC 604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.4.2 Trouble shooting DSQC 661 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.4.3 Trouble shooting DSQC 662 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Table of Contents
43HAC020738-001 Revision: K
© Copyright 2005-2010 ABB. All rights reserved.
5 Descriptions and background information 69
5.1 Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.1.1 LEDs in the Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.1.2 LEDs in the Drive Module for Drive System 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.1.3 LEDs in the Drive Module for Drive System 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6 Trouble shooting by Event log 83
Index 465

Overview of this manual
53HAC020738-001 Revision: K
© Copyright 2005-2010 ABB. All rights reserved.
Overview of this manual
About this manual This manual contains information, procedures and descriptions, for trouble shooting IRC5
based robot systems.
Usage This manual should be used whenever robot operation is interrupted by malfunction,
regardless of whether an error event log message is created or not.
Who should read this manual?
This manual is intended for the following personnel:
•Machine and robot operators qualified to perform very basic trouble shooting and
reporting to service personnel.
•Programmers qualified to write and change RAPID programs.
•Specialized trouble shooting personnel, usually very experienced service personnel,
qualified for methodically isolating, analyzing and correcting malfunctions within the
robot system.
Prerequisites The reader should:
•Have extensive experience in trouble shooting industrial electro-mechanical
machinery.
•Have in depth knowledge of the robot system function.
•Be familiar with the actual robot installation at hand, its surrounding equipment and
peripherals.
References
Reference: Document ID:
Product manual - IRC5 3HAC021313-001
Emergency safety information 3HAC027098-001
General safety information 3HAC031045-001
Operating manual - IRC5 with FlexPendant 3HAC16590-1
Operating manual - RobotStudio 3HAC032104-001
Operating manual - Getting started, IRC5 and RobotStudio 3HAC027097-001
Technical reference manual - System parameters 3HAC17076-1
Application manual - MultiMove 3HAC021272-001
Continues on next page

Overview of this manual
3HAC020738-001 Revision: K6
© Copyright 2005-2010 ABB. All rights reserved.
Revisions
Revision Description
-First edition.
AInformation has been added.
The document has been partly restructured.
BInformation on how to submit error report has been changed.
Information on RAPID change logs have been added.
Event log messages have been added.
CUpdated Event log messages.
DUpdated Event log messages.
EUpdated Event log messages.
FMinor corrections. Updated Event log messages.
GMinor corrections. Updated Event log messages.
HNew information in section Serial Measurement Unit regarding the battery
pack.
Moredetailed information about trouble shooting powersuppliesDSQC604,
661 and 662.
Removed safety I/O signals: DRV1PANCH1, DRV1PANCH2, DRV1SPEED.
New drive system introduced. Drive System 04 and Drive System 09 are
both described.
JReleased with RobotWare 5.13
The chapter Safety updated with:
• Updated safety signal graphics for the levels Danger and Warning,
see Safety signals in the manual on page 7.
• New safety labels on the manipulators, see Safety symbols on the
manipulator labels on page 9.
• Updated the graphic in the section DANGER - Live voltage inside
Drive Module! on page 17.
The contents in the following sections were updated:
• Corrections regarding drive system information in chapter Descrip-
tions and background information on page 65
• Restructured the chapters as per the new document startergy.
• Updated the graphic in the Recommended actions of the section No
voltage in service outlet on page 38.
• Updated the Possible causes in the section Problem starting the
FlexPendant on page 40.
• Updated the graphics in the section LEDs in the Control Module on
page 65.
• Updated the graphic in Possible causes of the section Problem
releasing Robot brakes on page 50.
KUpdated Event log messages.
Continued

1 Safety
1.1. Safety signals in the manual
73HAC020738-001 Revision: K
© Copyright 2005-2010 ABB. All rights reserved.
1 Safety
1.1. Safety signals in the manual
Introduction to safety signals
Thissection specifies all dangers that can arise when doing the work described in this manual.
Each danger consists of:
•A caption specifying the danger level (DANGER, WARNING,or CAUTION) and the
type of danger.
•A brief description of what will happen if the operator/service personnel do not
eliminate the danger.
•An instruction on how to eliminate the danger to simplify doing the work.
Danger levels The table below defines the captions specifying the danger levels used throughout this
manual.
Symbol Designation Significance
danger
DANGER Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
impact, fall from height, etc.
warning
WARNING Warns that an accident may occur if the instructions
are not followed that can lead to serious injury,
possibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
Electrical shock
ELECTRICAL
SHOCK Warns for electrical hazards which could result in severe personal injury or death.
caution
CAUTION Warns that an accident may occur if the instructions
are not followed that can result in injury and/or
damage to the product. It also applies to warnings of
risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping,
impact, fall from height, etc. Furthermore, it applies
to warnings that include function requirements when
fitting and removing equipment where there is a risk
of damaging the product or causing a breakdown.
Continues on next page

1 Safety
1.1. Safety signals in the manual
3HAC020738-001 Revision: K8
© Copyright 2005-2010 ABB. All rights reserved.
Electrostatic discharge
(ESD)
ELECTROSTATIC
DISCHARGE (ESD) Warns for electrostatichazards which could result in severe damage to the product.
Note
NOTE Describes important facts and conditions.
Tip
TIP Describes where to find additional information or
how to do an operation in an easier way.
Symbol Designation Significance
Continued

1 Safety
1.2. Safety symbols on the manipulator labels
93HAC020738-001 Revision: K
© Copyright 2005-2010 ABB. All rights reserved.
1.2. Safety symbols on the manipulator labels
Introduction to labels
This section describes safety symbols used on labels (stickers) on the manipulator.
Symbol are used in combinations on the labels, describing each specific warning. The
descriptions in this section are generic, the labels can contain additional information such as
values.
Types of labels Both the manipulator and the controller are marked with several safety and information
labels, containing important information about the product. The information is useful for all
personnel handling the manipulator system, for example during installation, service, or
operation.
The safety labels are language independent, they only use graphics. See Symbols on safety
labels on page 9.
The information labels can contain information in text (English, German, and French).
Symbols on safety labels
Symbol Description
xx0900000812
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply to
danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
xx0900000811
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping,
impact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
xx0900000839
Prohibition
Used in combinations with other symbols.
Continues on next page

1 Safety
1.2. Safety symbols on the manipulator labels
3HAC020738-001 Revision: K10
© Copyright 2005-2010 ABB. All rights reserved.
xx0900000813
Product manual
Read the product manual for details.
xx0900000816
Before dismantling see product manual
xx0900000815
Do not dismantle
Dismantling this part can cause injury.
xx0900000814
Extended rotation
This axis has extended rotation (working area) compared to
standard.
xx0900000808
Brake release
Pressing this button will release the brakes. This means that the
manipulator arm can fall down.
xx0900000810
Tip risk when loosening bolts
The manipulator can tip over if the bolts are not securely
fastened.
xx0900000817
Crush
Risk for crush injuries.
Symbol Description
Continued
Continues on next page

1 Safety
1.2. Safety symbols on the manipulator labels
113HAC020738-001 Revision: K
© Copyright 2005-2010 ABB. All rights reserved.
xx0900000818
Heat
Risk of heat that can cause burns.
xx0900000819
Moving robot
The robot can move unexpectedly.
xx0900000820
Brake release buttons
xx0900000821
Lifting bolt
xx0900000822
Lifting of robot
xx0900000823
Oil
Can be used in combination with prohibition if oil is not allowed.
Symbol Description
Continued
Continues on next page

1 Safety
1.2. Safety symbols on the manipulator labels
3HAC020738-001 Revision: K12
© Copyright 2005-2010 ABB. All rights reserved.
xx0900000824
Mechanical stop
xx0900000825
Stored energy
Warns that this part contains stored energy.
Used in combination with Do not dismantle symbol.
xx0900000826
Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.
xx0900000827
Shut off with handle
Use the power switch on the controller.
Symbol Description
Continued

1 Safety
1.3. Safety during trouble shooting
133HAC020738-001 Revision: K
© Copyright 2005-2010 ABB. All rights reserved.
1.3. Safety during trouble shooting
General Allnormalservice work; installation, maintenance andrepair work, isusually performed with
all electrical, pneumatic and hydraulic power switched off. All manipulator movements are
usually prevented by mechanical stops etc.
Trouble shooting work differs from this. While trouble shooting, all or any power may be
switched on, the manipulator movement may be controlled manually from the FlexPendant,
by a locally running robot program or by a PLC to which the system may be connected.
Dangers during trouble shooting
This implies that special considerations unconditionally must be taken when trouble
shooting:
•All electrical parts must be considered as live.
•The manipulator must at all times be expected to perform any movement.
•Since safety circuits may be disconnected or strapped to enable normally prohibited
functions, the system must be expected to perform accordingly.

1 Safety
1.4. Applicable safety standards
3HAC020738-001 Revision: K14
© Copyright 2005-2010 ABB. All rights reserved.
1.4. Applicable safety standards
Standards, EN ISO The manipulator system is designed in accordance with the requirements of:
1. There is a deviation from paragraph 6.2 in that only worst case stop distances and stop
times are documented.
2. Only robots with Protection Clean Room.
3. Only valid for arc welding robots. Replaces EN 61000-6-4 for arc welding robots.
European standards
Standard Description
EN ISO 12100 -1 Safety of machinery - Basic concepts, general principles for
design - Part 1: Basic terminology, methodology
EN ISO 12100 -2 Safety of machinery - Basic concepts, general principles for
design - Part 2: Technical principles
EN ISO 13849-1 Safety of machinery, safety related parts of control systems -
Part 1: General principles for design
EN ISO 13850 Safety of machinery - Emergency stop - Principles for design
EN ISO 10218-11Robots for industrial environments - Safetyrequirements -Part 1
Robot
EN ISO 9787 Manipulating industrial robots, Coordinate systems and motion
nomenclatures
EN ISO 9283 Manipulating industrial robots, Performance criteria and related
test methods
EN ISO 14644-12Classification of air cleanliness
EN ISO 13732-1 Ergonomics of the thermal environment - Part 1
EN 61000-6-4
(option 129-1) EMC, Generic emission
EN 61000-6-2 EMC, Generic immunity
EN IEC 60974-13Arc welding equipment - Part 1: Welding power sources
EN IEC 60974-103Arc welding equipment - Part 10: EMC requirements
EN 60204-1 Safety of machinery - Electrical equipment of machines - Part 1
General requirements
IEC 60529 Degrees of protection provided by enclosures (IP code)
Standard Description
EN 614-1 Safety of machinery - Ergonomic design principles - Part 1:
Terminology and general principles
EN 574 Safety of machinery - Two-hand control devices - Functional
aspects - Principles for design
EN 953 Safety of machinery - General requirements for the design and
construction of fixed and movable guards
Continues on next page

1 Safety
1.4. Applicable safety standards
153HAC020738-001 Revision: K
© Copyright 2005-2010 ABB. All rights reserved.
Other standards
Standard Description
ANSI/RIA R15.06 Safety Requirements for Industrial Robots and Robot Systems
ANSI/UL 1740
(option 429-1) Safety Standard for Robots and Robotic Equipment
CAN/CSA Z 434-03
(option 429-1) Industrial Robots and Robot Systems - General Safety Require-
ments
Continued

1 Safety
1.5.1. DANGER - Robot without axes' holding brakes are potentially lethal!
3HAC020738-001 Revision: K16
© Copyright 2005-2010 ABB. All rights reserved.
1.5 Safe Trouble Shooting
1.5.1. DANGER - Robot without axes' holding brakes are potentially lethal!
Description Since the robot arm system is quite heavy, especially on larger robot models, it is dangerous
if the holding brakes are disconnected, faulty, worn or in any way rendered non-operational.
For instance, a collapsing IRB 7600 arm system may kill or seriously injure a person standing
beneath it.
Elimination
Action Info/illustration
1. If you suspect that the holding brakes are
non-operational, secure the robot arm
system by some other means before
working on it.
Weight specifications etc. may be found in
the Product manual of each robot model.
2. If you intentionally render the holding
brakes non-operational by connecting an
external voltage supply, the utmost care
must be taken!
DANGER!
NEVER stand inside the robot working
area when disabling the holding brakes
unless the arm system is supported by
some other means!
DANGER!
Under no circumstance stand beneath any
of the robot’s axes!
How to correctly connect an external
voltage supply is detailed in the Product
manual of each robot model.

1 Safety
1.5.2. DANGER - Live voltage inside Drive Module!
173HAC020738-001 Revision: K
© Copyright 2005-2010 ABB. All rights reserved.
1.5.2. DANGER - Live voltage inside Drive Module!
Description The Drive Module has live voltage potentially accessible directly behind the rear covers and
inside the front cover, even when the main switches have been switched off.
en1000000049
en1000000050
ALive voltage at transformer terminals even if the main power switches have been
switched off.
BLive voltage at Motors ON terminals even if the main power switches have been
switched off.
A
B
Continues on next page

1 Safety
1.5.2. DANGER - Live voltage inside Drive Module!
3HAC020738-001 Revision: K18
© Copyright 2005-2010 ABB. All rights reserved.
Elimination Read this information before opening the rear cover of either module.
Step Action
1. Make sure the incoming mains power supply has been switched off.
2. Use a voltmeter to verify that there is not voltage between any of the terminals.
3. Proceed with the service work.
Continued