ABB M2004 User instructions

System Settings
Welding Robot Station
M2004, IRC5
3HEA 802352-001 Rev. A

The information in this document is subject to alteration without prior notice and should not be regarded
as an undertaking from ABB Automation Technologies AB. ABB Automation Technologies AB assumes
no responsibility for errors that may occur in this document.
ABB Automation Technologies AB bears no responsibility for damage that is a consequence of using this
document or the software or hardware described in this document.
The document, or parts of it, may not be reproduced or copied without prior permission from ABB Auto-
mation Technologies AB. It may neither be imparted to a third party nor otherwise be used without autho-
rization. Infringement hereof will be subject to action in accordance with applicable laws.
Further copies of this document can be obtained from ABB Automation Technologies AB at current prices.
© Copyright 2005 ABB All right reserved.
ABB Automation Technologies AB
Robotics
SE-72168 Västerås
Sweden

3HEA 802352-001 Rev. A i
Contents
System Settings
M2004, IRC5 1 Safety instructions 3
1.1 Description 3
1.2 Warning symbols (signals) 4
1.2.1 DANGER – Ensure that the main power switch is turned off. 5
1.2.2 WARNING – The unit is sensitive to ESD. 6
2 Calibrating the robot and the additional axes 7
2.1 Updating the revolution counter 7
2.2 Manual setting of the calibration values 9
2.3 Recalibrating the axes 12
2.3.1 Positioners of the types A, L and MTC 12
3 Definition of the tool data (tload) 15
3.1 Definition of the tool data (tload) 15
3.1.1 Welding gun with swan neck: 15
3.2 Setup welding gun without BullsEye® 16
4 Speed data for external axes 17
5 Drivers 19
5.1 Introduction 19
5.1.1 General 19
5.1.2 Parts handling 19
5.1.3 Advanced part 19
5.1.4 RAPID instructions 21
5.1.5 Safety position 23
5.2 Calibration of the station interchange unit for positioner IRBP26
5.2.1 Positioner IRBP with mechanical stop 26
5.2.2 Positioner IRBP without mechanical stop 29
5.3 Work positions 33
5.3.1 Introduction 33
5.3.2 Load position 33
5.3.3 Process position 36
5.3.4 Service position 38
6 Identification of load data for positioners IRBP 41
6.1 Load Identification for IRBP L /C 41
6.1.1 Parameters and movements 42
6.2 Load Identification for IRBP K 43
6.3 Load Identification for IRBP R 44

ii 3HEA 802352-001 Rev. A
6.4 Load Identification for IRBP A, B and D 45
7 Define payload for a mechanical unit 47
7.1 MechUnitLoad 47
7.2 Program execution 48
7.3 Limitations 50
7.4 Syntax 50
7.5 Related information 51

Safety instructions
3HEA 802352-001 Rev. A 3
1 Safety instructions
A robot is heavy and extremely powerful regardless of its speed. A stoppage or
longer stop can be followed by rapid, dangerous movements. Even if the robot's
pattern of movement is predetermined, an external signal can affect the movement
sequence, resulting in unanticipated movement.
It is therefore important that all safety instructions are observed when entering a
safety supervised area.
1.1 Description
Safety instructions can be found under tab 1 in the AW system manual for all steps
that involve risk for personal injury or material damage. In addition, they are
included in the instructions for each step.
General warnings, where the intention is to avoid problems, are only included in the
pertinent instructions.
Reference document
All personnel working with the welding robot system must have full understanding of the
applicable safety instructions.
Document Described in:
Related safety instructions. AW System manual, chapter introduction and safety

Safety instructions
Warning symbols (signals)
43HEA 802352-001 Rev. A
1.2 Warning symbols (signals)
Symbol
explanations The different types of warnings are set out in the following chapters according to the
table below:
The safety information in the document must not be interpreted as a guarantee from
ABB that the equipment cannot cause accidents or injury, even if all the safety
instructions have been observed.
Symbol Name Meaning
!
Danger Warning that serious or life-threatening personal injury and/or
serious damage to the product will occur if the instructions are
not followed.
Warning Warns of the risk of personal injury or serious damage to the
product. Always follow the instructions that accompany this
symbol.
Electric shock Warns of possible electric shock that can cause life-threatening
or serious personal injury. Always follow the instructions that
accompany this symbol.
Caution Draws your attention to the fact that damage to the product may
occur if an action is not performed or is performed incorrectly.
Static
electricity ESD The ESD symbol indicates a risk of static electricity that may cause serious damage to the product.
Note Information about important parts.
Tips Thissymbolreferstoaninstructionprovidingfurtherinformation
on a particular step.

Safety instructions
DANGER – Ensure that the main power switch is turned off.
3HEA 802352-001 Rev. A 5
1.2.1 DANGER – Ensure that the main power switch is turned off.
Description
Work with high voltage entails a potential lethal hazard. Persons subjected to high
voltages can suffer heart failure, burns or other serious injuries. To avoid such
injuries, never begin a job without first eliminating the risks to safety. These are
descried below.
Elimination
Action Info/Illustration
1. Turnoffthemainpowerswitchatthe
control module.
The main power switch on the
control module switches off the
control voltage to all the drive
modules.
2. Turnoffthemainpowerswitch(work
switch) on the respective drive
module to switch off the feed
voltage.
3. Single robot stations All voltage is lost when the main switch on
the drive module (DM1) is switched off.
1
2

Safety instructions
WARNING – The unit is sensitive to ESD.
63HEA 802352-001 Rev. A
1.2.2 WARNING – The unit is sensitive to ESD.
Description
ESD (electrostatic discharge) is the transfer of electrostatic charges between two
objects with varying charges, either through direct contact or through an electrical
field.
The discharge contains very little electricity and is therefore not hazardous to
humans, however, electronics can be damaged by the high voltages.
Elimination
Location of attachment point for ESD bracelet
Button (A/B) for the ESD bracelet is located on the computer unit in the control
module/drive module. The location is shown in the following figure.
Action Info/Illustration
1. Use an ESD bracelet. The bracelet must be regularly tested to
ensure that it is undamaged and functions
properly.
2. Use an ESD-protected floor mat. The mat must be grounded through a voltage
regulating resistor.
3. Use an ESD-protected table mat. The mat shallproduce a controlled discharge
of static electricity and must be grounded.
xx0400001061
Figure 1 Location of attachment point for ESD bracelet
Item Name
A Attachment point for ESD bracelet in the control module.
B Attachment point for ESD bracelet in the drive module.
A
B

Calibrating the robot and the additional axes
Updating the revolution counter
3HEA 802352-001 Rev. A 7
2 Calibrating the robot and the additional axes
Thischapterdescribeshow you update the revolution counter, make manual settings
for calibration values and recalibrate the axes.
2.1 Updating the revolution counter
This measure is necessary when you have entered the calibration values manually
or for some reason need to update one or more of the axes' revolution counters
(resolver) against the synchronization position.
Usually the programmed positions are not affected by an update. If this happens the
entered values may be incorrect or the axis has been updated before programming
at an incorrect position i.e. not by the synchronization markings.
Action Info/Illustration
1. Move the robot's and positioner's axes to their respective zero positions (synchroni-
zation marking).
2. Tap ABB, to open the service window.
3. Tap Calibration.
4. Tap on the mechanical unit to be cali-
brated.
When the unit concerned is not
visible in the window, use the scroll
bar arrows, in the lower part of the
window.
(
2)
(
3)
(
4)

Calibrating the robot and the additional axes
Updating the revolution counter
83HEA 802352-001 Rev. A
5. Tap Revolution Counters.
6. Tap Update Rev. Counters.
7. The system awaits a response:
• Tap YES if you want to proceed.
8. Select, by tapping, the axes to be
updated.
• Tap Select All to include all the
mechanical unit’s axes.
9. Tap Update.
Action Info/Illustration
(
5)
(
6)
(
7)
(
8)
(
9)